Start-Up, Operation and Maintenance Instructions

Transcription

23XRV
Hermetic Screw Liquid Chillers with
PIC III Controls
50/60 Hz
HFC-134a
Start-Up, Operation and Maintenance
Instructions
SAFETY CONSIDERATIONS
Screw liquid chillers are designed to provide safe and
reliable service when operated within design specifications.
When operating this equipment, use good judgment and
safety precautions to avoid damage to equipment and property or injury to personnel.
Be sure you understand and follow the procedures and
safety precautions contained in the chiller instructions, as
well as those listed in this guide.
DO NOT VENT refrigerant relief valves within a building. Outlet from
rupture disc or relief valve must be vented outdoors in accordance with
the latest edition of ANSI/ASHRAE 15 (American National Standards
Institute, American Society of Heating, Refrigeration, and Air Conditioning Engineers), latest edition. The accumulation of refrigerant in an
enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15,
especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities,
unconsciousness, or death. Misuse can be fatal. Vapor is heavier than air
and reduces the amount of oxygen available for breathing. Product
causes eye and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a chiller for
any purpose. Oxygen gas reacts violently with oil, grease, and other
common substances.
NEVER EXCEED specified test pressures. VERIFY the allowable test
pressure by checking the instruction literature and the design pressures
on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and
functioning before operating any chiller.
RISK OF INJURY OR DEATH by electrocution. High voltage is
present on motor leads even though the motor is not running. Open the
power supply disconnect before touching motor leads or terminals.
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until
all refrigerant (liquid and vapor) has been removed from chiller. Traces
of vapor should be displaced with dry air or nitrogen and the work area
should be well ventilated. Refrigerant in contact with an open flame
produces toxic gases.
DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the
entire assembly.
DO NOT work on high-voltage equipment unless you are a qualified
electrician.
DO NOT WORK ON electrical components, including control centers,
switches, starters, or oil heater until you are sure ALL POWER IS
OFF and no residual voltage can leak from capacitors or solid-state
components.
LOCK OPEN AND TAG electrical circuits during servicing. IF
WORK IS INTERRUPTED, confirm that all circuits are deenergized
before resuming work.
DO NOT syphon refrigerant.
AVOID SPILLING liquid refrigerant on skin or getting it into the eyes.
USE SAFETY GOGGLES. Wash any spills from the skin with soap
and liquid. If liquid refrigerant enters the eyes, IMMEDIATELY
FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder.
Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to
refill them. It is DANGEROUS AND ILLEGAL. When cylinder is
emptied, evacuate remaining gas pressure, loosen the collar, and
unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the
chiller. The introduction of the wrong refrigerant can cause damage or
malfunction to this chiller.
Operation of this equipment with refrigerants other than those cited
herein should comply with ANSI/ASHRAE 15 (latest edition).
Contact Carrier for further information on use of this chiller with other
refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller
is under pressure or while chiller is running. Be sure pressure is at
0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs, and other
relief devices AT LEAST ONCE A YEAR. If chiller operates in a corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
device when corrosion or build-up of foreign material (rust, dirt, scale,
etc.) is found within the valve body or mechanism. Replace the device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring.
Sudden release of the spring can cause it and objects in its path to act as
projectiles.
DO NOT STEP on refrigerant lines. Broken lines can whip about and
release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or staging.
Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move
inspection covers or other heavy components. Even if components are
light, use mechanical equipment when there is a risk of slipping or
losing your balance.
BE AWARE that certain automatic start arrangements CAN ENGAGE
THE COMPRESSOR, TOWER FAN, OR PUMPS. Open the disconnect ahead of the starter, tower fan, or pumps. Shut off the chiller or
pump before servicing equipment.
USE only repair or replacement parts that meet the code requirements
of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines,
water, gases, or semisolids without the permission of your process control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been
completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other
items have been removed before rotating any shafts.
DO NOT LOOSEN a packing gland nut before checking that the nut
has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pressure
relief device to prevent a build-up of condensate or rain water.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 532-310
Printed in U.S.A.
Form 23XRV-1SS
Pg 1
9-06
Replaces: New
Book 2
Tab 5e
CONTENTS
Page
Vaporizer Temperature Control
COMPRESSOR ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil Sump Temperature Control
COMPRESSOR OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil Sump Temperature Control
COMPRESSOR ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Remote Start/Stop Contacts . . . . . . . . . . . . . . . . . . . . . 38
Spare Safety and Spare Temperature Inputs. . . . . 38
Spare Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 39
4 to 20 mA Kilowatt Output . . . . . . . . . . . . . . . . . . . . . . 39
Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 39
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 39
Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 39
Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 39
Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 40
Liquid/Brine Temperature Reset . . . . . . . . . . . . . . . . . 40
• RESET TYPE 1
• RESET TYPE 2
• RESET TYPE 3
Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 40
Hot Gas Bypass (Optional) Algorithm . . . . . . . . . . . 40
Head Pressure Output Reference. . . . . . . . . . . . . . . . 41
Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
• COMMON POINT SENSOR INSTALLATION
• CHILLER COMMUNICATION WIRING
• LEAD/LAG OPERATION
• FAULTED CHILLER OPERATION
• LOAD BALANCING
• AUTO. RESTART AFTER POWER FAILURE
Attach to Network Device Control . . . . . . . . . . . . . . . 44
• ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
• TO ACCESS THE SERVICE SCREENS
• TO LOG OUT OF DEVICE
• HOLIDAY SCHEDULING
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-48
Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Automatic Soft Stop Amps Threshold . . . . . . . . . . . 47
Chilled Liquid Recycle Mode . . . . . . . . . . . . . . . . . . . . 47
Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 48-64
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 48
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 48
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Tighten All Gasketed Joints . . . . . . . . . . . . . . . . . . . . . 48
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 49
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Chiller Dehydration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Inspect Liquid Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Check Optional Pumpout Compressor
Liquid Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Identify the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
• IDENTIFYING THE DRIVE BY PART NUMBER
Check Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . 57
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Ground Fault Troubleshooting. . . . . . . . . . . . . . . . . . . 58
Carrier Comfort Network® Interface . . . . . . . . . . . . . 58
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 4
23XRV CHILLER FAMILIARIZATION. . . . . . . . . . . . . 4-8
Chiller Identification Nameplate . . . . . . . . . . . . . . . . . . 4
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 8
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . 8-10
MOTOR COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . 10
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
• ANALOG SIGNAL
• DIGITAL SIGNAL
General Controls Overview . . . . . . . . . . . . . . . . . . . . . . 12
PIC III System Components . . . . . . . . . . . . . . . . . . . . . 12
• INTERNATIONAL CHILLER VISUAL
CONTROLLER (ICVC)
• CHILLER CONTROL MODULE (CCM)
• VFD POWER MODULE
• VFD GATEWAY MODULE
• OIL HEATER CONTACTOR (1C)
• OIL PUMP CONTACTOR (2C)
• HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional)
• VFD REFRIGERANT COOLING SOLENOID
VALVE (5C)
• VAPORIZER HEATER CONTACTOR (6C)
• CONTROL TRANSFORMERS (T1, T2)
ICVC Operation and Menus. . . . . . . . . . . . . . . . . . . . . . 15
• GENERAL
• ALARMS AND ALERTS
• ICVC MENU ITEMS
• BASIC ICVC OPERATIONS (Using the Softkeys)
• TO VIEW STATUS
• OVERRIDE OPERATIONS
• TIME SCHEDULE OPERATION
• TO VIEW AND CHANGE SET POINTS
• SERVICE OPERATION
PIC III System Functions . . . . . . . . . . . . . . . . . . . . . . . . 34
• CAPACITY CONTROL
• FORCED
• NORMAL CONDITIONS
• CAPACITY INCREASE
• CAPACITY DECREASE
• ECL CONTROL OPTION
• CHILLED LIQUID DEADBAND
• PROPORTIONAL BANDS AND PROPORTIONAL
GAIN
• DEMAND LIMITING
• CHILLER TIMERS
• OCCUPANCY SCHEDULE
Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Shunt Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Compressor Minimum Speed Override . . . . . . . . . . 36
2
CONTENTS (cont)
Page
Chillers With Storage Tanks . . . . . . . . . . . . . . . . . . . . . 70
• TRANSFER REFRIGERANT FROM PUMPOUT
STORAGE TANK TO CHILLER
• TRANSFER REFRIGERANT FROM CHILLER TO
PUMPOUT STORAGE TANK
• CHILLERS WITH ISOLATION VALVES
• DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .72,73
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 72
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 72
Refrigerant Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Test After Service, Repair, or Major Leak . . . . . . . . 72
• REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Refrigerant Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 73
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 73
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 73
Check the Lubrication System . . . . . . . . . . . . . . . . . . 73
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-78
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspect the Control Center . . . . . . . . . . . . . . . . . . . . . . 73
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Changing Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . 73
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Refrigerant Filter/Drier . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Oil Strainers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
VFD Refrigerant Strainer . . . . . . . . . . . . . . . . . . . . . . . . 74
Vaporizer Refrigerant Return Line Orifice . . . . . . . 74
Compressor Inlet Bearing Oil Orifice . . . . . . . . . . . . 74
Inspect Condenser Refrigerant Float System. . . . 75
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 77
Compressor Bearing Maintenance . . . . . . . . . . . . . . 77
Compressor Rotor Check . . . . . . . . . . . . . . . . . . . . . . . 77
Motor Insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Inspect the Heat Exchanger Tubes . . . . . . . . . . . . . . 77
• COOLER
• CONDENSER
Water/Brine Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Water/Brine Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Inspect the Control Center . . . . . . . . . . . . . . . . . . . . . . 77
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 78
Optional Pumpout System Maintenance. . . . . . . . . 78
• OPTIONAL PUMPOUT COMPRESSOR
OIL CHARGE
• OPTIONAL PUMPOUT SAFETY
CONTROL SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 78
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 78-117
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Checking the Display Messages. . . . . . . . . . . . . . . . . 79
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 79
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers . . . . . . . . . . . . . . . . 79
• COOLER CONDENSER PRESSURE TRANSDUCER
AND LIQUIDSIDE FLOW DEVICE CALIBRATION
• TRANSDUCER REPLACEMENT
Page
Power Up the Controls and Check the
Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 59
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 59
Input the Local Occupancy Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 59
• PASSWORD
• INPUT TIME AND DATE
• CHANGE ICVC CONFIGURATION IF NECESSARY
• TO CHANGE THE PASSWORD
• TO CHANGE THE ICVC DISPLAY FROM ENGLISH
TO METRIC UNITS
• MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS
IF NECESSARY
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Pressure Transducer and Optional Flow
Device Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
• ZERO POINT CALIBRATION
• HIGH END CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 62
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 62
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 63
• CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
• CHILLER EQUALIZATION WITH PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64,65
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check Oil Pressure and Compressor Stop . . . . . . 65
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 65
Check Chiller Operating Condition . . . . . . . . . . . . . . 65
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 65
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND
PUMPOUT SYSTEM
• COMPRESSOR ASSEMBLY
• COMPRESSOR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP, OPERATION AND
MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 66-68
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66
To Start The Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check the Running System . . . . . . . . . . . . . . . . . . . . . 66
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
• FAILURE TO STOP
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 66
Preparation for Extended Shutdown . . . . . . . . . . . . 66
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-72
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Operating the Optional Pumpout Unit . . . . . . . . . . . 69
3
CONTENTS (cont)
ABBREVIATIONS AND EXPLANATIONS
Page
Control Algorithms Checkout Procedure . . . . . . . . 80
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 98
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 98
• INPUTS
• OUTPUTS
Replacing Defective Processor Modules . . . . . . . 101
• INSTALLATION
Gateway Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 102
• DRIVE STATUS INDICATOR
• MS STATUS INDICATOR
• NET A STATUS INDICATOR
• NET B STATUS INDICATOR
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
APPENDIX A — ICVC PARAMETER INDEX . . 118-126
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
INITIAL START-UP CHECKLIST FOR
23XRV HERMETIC SCREW
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-12
Frequently used abbreviations in this manual include:
CCM — Chiller Control Module
CCN — Carrier Comfort Network
CCW — Counterclockwise
CSM — Chillervisor System Manager
CW
— Clockwise
DPI
— LF2 VFD Drive Peripheral Interface Board
ECDL — Entering Condenser Liquid
ECL — Entering Chilled Liquid
EMS — Energy Management System
HGBP — Hot Gas Bypass
ICVC — International Chiller Visual Controller
IGBT — Insulated Gate Bipolar Transistor
I/O
— Input/Output
KAIC — Kiloamps Interrupt Capacity
LCD — Liquid Crystal Display
LCDL — Leaving Condenser Liquid
LCL — Leaving Chilled Liquid
LED — Light-Emitting Diode
LEI
— Local Equipment Interface Translator
LF2
— Reliance LiquiFlo™ 2 VFD with Active
Rectifier
OIM — Reliance Operator Interface Module
OLTA — Overload Trip Amps
PIC III — Product Integrated Control III
RLA — Rated Load Amps
RS485 — Communications Type used by ICVC and CCM
SCR — Silicon Controlled Rectifier
SI
— International System of Units
SIO
— Sensor Input/Output
TB1
— Control Center Terminal Block 1
TB2
— Control Center Terminal Block 2
VFD — Variable Frequency Drive
INTRODUCTION
Prior to initial start-up of the 23XRV chiller, those involved
in the start-up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data.
This book is outlined to familiarize those involved in the startup, operation and maintenance of the unit with the control system before performing start-up procedures. Procedures in this
manual are arranged in the sequence required for proper chiller
start-up and operation.
Words printed in all capital letters or in italics may be
viewed on the International Chiller Visual Controller (ICVC)
(e.g., LOCAL, CCN, ALARM, etc.).
Words printed in both all capital letters and italics can also
be viewed on the ICVC and are parameters (e.g., CONTROL
MODE, COMPRESSOR START RELAY, etc.) with associated
values (e.g., modes, temperatures, percentages, pressures, on,
off, etc.).
Words printed in all capital letters and in a box represent
softkeys on the ICVC control center (e.g., ENTER , EXIT ,
INCREASE , QUIT , etc.).
This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards or
modules. Control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to dissipate body electrostatic charge before working inside control center.
Use extreme care when handling tools near circuit boards
and when connecting or disconnecting terminal plugs. Circuit boards can be damaged easily. Always hold boards by
the edges, and avoid touching components and connections.
This equipment uses, and can radiate, radio frequency
energy. If not installed and used in accordance with the
instruction manual, it may interfere with radio communications. This equipment has been tested and found to comply
with the limits for a Class A computing device pursuant to
Subpart J of Part 15 of FCC Rules, which are designed to
provide reasonable protection against such interference
when operated in a commercial environment. Operation of
this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be
required to take whatever measures may be required to correct the interference.
Always store and transport replacement or defective boards
in an anti-static shipping bag.
Factory-installed additional components are referred to as
options in this manual; factory-supplied but field-installed additional components are referred to as accessories.
The chiller software part number of the 23XRV unit is located on the back of the ICVC.
23XRV CHILLER FAMILIARIZATION
(Fig. 1, 2, and 3)
Chiller Identification Nameplate — The chiller
identification nameplate is located on the right side of the
chiller control center.
System Components — The
components include
cooler and condenser, heat exchangers in separate vessels,
motor-compressor, lubrication system, control center, and
optional economizer. All connections from pressure vessels
have threads, flanges, or victaulic grooves to enable each component to be pressure tested during factory assembly.
4
S – Special
23XRV – High Efficiency
Variable Speed Screw Chiller
Not Used
Voltage Code
3 – 380-3-60
4 – 416-3-60
5 – 460-3-60
9 – 400-3-50
Cooler Size*
30-32
35-37
40-42
45-47
50-52
55-57
Drive
Frame
AA
BA
BB
CC
Condenser Size*
30-32
35-37
40-42
45-47
50-52
55-57
Motor Code
P
Q
R
S
T
U
V
Economizer Option
E – With Economizer
N – No Economizer
R – Compressor
Rectifier Max
Input Amps†
440
520
520
608
Inverter Max
Output Amps†
442
442
520
608
Max Motor Amps
265
283
306
334
368
421
440
a23-1533
*First number denotes frame size.
†Maximum limits only. Additional application limits apply that may reduce these ampacities.
Fig. 1 — Model Number Identification
1
2
4
3
21
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
5
20
6
7
8
12
10
11
9
13
19
a23-1548
16
18
15
14
17
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Motor Terminal Cover Plate
Variable Frequency Drive
International Chiller Visual Controller (ICVC)
Discharge Pipe/Relief Valve
Condenser
Oil Reclaim Actuator
Vaporizer Sight Glass
Oil Filter Assembly (Hidden)
Vaporizer
Oil Sump Charging/Drain Valve
Oil Sump
Condenser Refrigerant Pumpout Valve
Condenser Float Chamber
Cooler Inlet Isolation Valve
ASME Nameplate, Economizer (Hidden)
Filter Drier
Oil Sump Heater
Condenser Supply/Return End Waterbox
Cooler Supply/Return End Waterbox
Motor Cooling Supply Line
VFD Circuit Breaker/Disconnect
Fig. 2 — Typical 23XRV Component Locations
5
22
23
24
25
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
26
41
40 39 38
37
36 35 34
33
a23-1549
42
43
27
28
32 31
44
30
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Discharge Pipe Assembly
Compressor Discharge Check Valve Access Cover
Condenser Relief Valves with Three-Way Valve
Refrigerant Charging Valves
Cooler Relief Valve
Tubesheet Mounting Brackets
Typical Waterbox Drain Coupling
ASME Nameplate, Condenser
Oil Pump
Oil Pump Inlet Strainer
Strainer Housing Sight Glass
Discharge Isolation Valve (Option or Accessory)
Machine Electrical Data Nameplate
Refrigeration Machine Nameplate
Oil Sump Sight Glass
Filter Drier Isolation Valve with Schrader
Economizer
Motor Cooling Sight Glass
Filter/Drier Isolation Valve
Vaporizer Drain Sight Glass
29
45
46
47
42 — VFD Cold Plate Refrigeration Inlet Connection
(Outlet Hidden)
43 — VFD Refrigerant Cooling Solenoid Valve
44 — Compressor Nameplate
45 — Compressor Lubrication Block
46 — Economizer Muffler
47 — Vaporizer Condenser Gas Isolation Valve
48 — Hot Gas Bypass Isolation and Trim Valve
49 — VFD Cooling Refrigerant Strainer
50 — Cooler Refrigerant Pumpout Valve
51 — ASME Nameplate, Cooler
48
49
50
a23-1550
51
Fig. 2 — Typical 23XRV Component Locations (cont)
6
6
2 3
4 5
1
1
2
3
4
5
6
7
8
9
—
—
—
—
—
—
—
—
—
Condenser Pressure
Evaporator Pressure
Compressor Discharge Temperature
Compressor Discharge Pressure
Compressor Discharge High Pressure Switch
Compressor Motor Winding Temperature (Hidden)
Evaporator Refrigerant Liquid Temperature (Hidden)
Condenser Liquid Temperature
Condenser Liquid Flow (Optional)
9
7
a23-1551 8
10
11
12 13
14
15
20
16
17
19
a23-1552
10 — Inductor Temperature Switch
(Inside VFD Enclosure)
11 — VFD Rectifier Temperature
(Inside Power Module)
12 — VFD Cold Plate Temperature
(Inside VFD Enclosure)
13 — VFD Inverter Temperature
(Inside Power Module)
14 — Humidity Sensor (Inside VFD Enclosure)
15 — Oil Pressure Leaving Filter (Hidden)
16 — Oil Sump Pressure (Hidden)
17 — Oil Sump Temperature (Hidden)
18 — Vaporizer Temperature
19 — Evaporator Liquid Temperature
20 — Evaporator Liquid Flow (Optional)
18
18
Fig. 3 — Typical 23XRV Sensor Locations
7
Cooler — The cooler (also known as the evaporator) is
REFRIGERATION CYCLE
maintained at low temperature/pressure so that evaporating
refrigerant can remove heat from the liquid flowing through its
internal tubes.
The compressor continuously draws refrigerant vapor from
the cooler. As the compressor suction reduces the pressure in
the cooler, the remaining refrigerant boils at a fairly low temperature (typically 38 to 42 F [3 to 6 C]). The energy required
for boiling is obtained from the liquid flowing through the
cooler tubes. With heat energy removed, the liquid becomes
cold enough for use in an air-conditioning circuit or process
liquid cooling.
After absorbing heat from the chilled liquid, the refrigerant
vapor is compressed. Compression adds still more energy, and
the refrigerant is quite warm (typically 90 to 130 F [32 to
54 C]) when it is discharged from compressor into condenser.
Relatively cool (typically 65 to 85 F [18 to 29 C]) liquid
flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid, refrigerant.
The liquid refrigerant in the condenser passes through
orifices into the FLASC (Flash Subcooler) chamber (Fig. 6).
Since the FLASC chamber is at a lower pressure, part of the
liquid refrigerant flashes to vapor, thereby cooling the remaining liquid. The FLASC vapor is recondensed on the tubes
which are cooled by entering condenser liquid. The liquid then
passes through a float valve assembly which forms a liquid seal
to keep FLASC chamber vapor from entering the cooler.
An optional economizer can be installed between the
condenser and cooler. In this case, an in-line orifice on the
economizer drain flange meters the refrigerant liquid into the
cooler. Pressure in this chamber is intermediate between
condenser and cooler pressures. At this lower pressure, some of
the liquid refrigerant flashes to gas, cooling the remaining
liquid. The flash gas, having absorbed heat, is returned directly
to the compressor at a point after suction cutoff (Fig. 7). Here it
is mixed with gas from the suction cut-off point to produce an
increase in the mass flow of refrigerant transported and
compressed without either an increase in suction volume or a
change in suction temperature.
The cooled liquid refrigerant in the economizer is metered
through an orifice into the cooler. Because pressure in the cooler is lower than economizer pressure, some of the liquid flashes
and cools the remainder to evaporator (cooler) temperature.
The cycle is now complete.
Condenser — This vessel is located underneath the
compressor. The condenser operates at a higher temperature/
pressure than the cooler and has liquid flowing through its
internal tubes to remove heat from the refrigerant.
Motor-Compressor — The motor-compressor maintains system temperature/pressure differences and moves the
heat carrying refrigerant from the cooler to the condenser. See
Fig. 4.
Muffler — The muffler provides acoustical attenuation. A
check valve just downstream of the muffler prevents reverse
compressor rotation during shutdown.
Control Center — The control center is the user interface for controlling the chiller and regulating the chiller’s
capacity to maintain the proper chilled liquid temperature. See
Fig. 5. The control center:
• registers cooler, condenser, and lubricating system pressures
• shows chiller operating condition and alarm shutdown
conditions
• records the total chiller operating hours, starts, and the
number of hours the chiller has been currently running
• sequences chiller start, stop, and recycle under microprocessor control
• provides access to other Carrier Comfort Network® devices
• provides machine protection
Storage Vessel (Optional) — Two sizes of storage
vessels are available. The vessels have double relief valves,
a magnetically coupled dial-type refrigerant level gage, a
1-in. FPT drain valve, and a 1/2-in. male flare vapor connection
for the pumpout unit. A 30-in.-0-400 psi (–101-0-2750 kPa)
gage is also supplied with each unit.
NOTE: If a storage vessel is not used at the jobsite, factoryinstalled optional isolation valves may be used to isolate the
chiller charge in either the cooler or condenser. An optional
pumpout compressor system is used to transfer refrigerant
from vessel to vessel.
DISCHARGE
COMPRESSOR LUBRICATION BLOCK
MOTOR TERMINAL
ACCESS COVER
MOTOR TERMINALS
MOTOR
COOLING
INLET
FLANGE
MOTOR COOLING
DRAIN
a23-1619
Fig. 4 — Compressor
8
ECONOMIZER
PORT
STANDARD
65 KAIC
CIRCUIT
BREAKER
OPTIONAL
100 KAIC
CIRCUIT BREAKER
(SHIPPED LOOSE
INSIDE OF CONTROL
CENTER FOR FIELD
INSTALLATION)
a23-1620
Fig. 5 — Standard and 100-KAIC Circuit Breaker Control Center
COOLER
REFRIGERANT
ISOLATION
VALVE (OPTIONAL)
VFD
REFRIGERANT
COOLING
ISOLATION
VALVE
HGBP ISOLATION VALVE (OPTIONAL)
MOTOR
VFD
COLD
PLATE
VFD
REFRIGERANT
COOLING
SOLENOID
VALVE
HGBP
SOLENOID
VALVE
COMPRESSOR
STRAINER
VFD
REFRIGERANT
COOLING
ISOLATION
VALVE
FILTER DRIER
CONDENSER
ISOLATION
VALVE (OPTIONAL)
FILTER DRIER
ISOLATION
VALVES
CONDENSER
FLOAT VALVE BUBBLER LINE
a23-1621
Fig. 6 — Refrigerant Flow Schematic (Without Optional Flash Economizer)
9
COOLER
HGBP ISOLATION
VALVE (OPTIONAL)
HGBP
SOLENOID
VALVE
VFD
REFRIGERANT
COOLING
ISOLATION
VALVE
ECONOMIZER MUFFLER
MOTOR
VFD
REFRIGERANT
COOLING
VFD
SOLENOID
COLD
VALVE
PLATE
VFD
REFRIGERANT
COOLING
ISOLATION
VALVE
FLASH
ECONOMIZER
STRAINER
COMPRESSOR
FILTER DRIER
ORIFICE
FILTER
DRIER ISOLATION
VALVES
FLOAT VALVE
CONDENSER
FLOAT VALVE BUBBLER LINE
a23-1622
Fig. 7 — Refrigerant Flow Schematic (With Optional Flash Economizer)
MOTOR COOLING CYCLE
LUBRICATION CYCLE
One half of the motor is cooled by suction gas while the
other half is cooled by liquid refrigerant taken from the bottom
of the condenser vessel. The flow of liquid refrigerant is maintained by the pressure differential that exists due to compressor
operation. The refrigerant flows through an isolation valve,
in-line filter/drier, and a sight glass/moisture indicator
(dry-eye), into the motor through the motor spray nozzle. See
Fig. 6 or 7.
The motor spray nozzle is orificed to control refrigerant
flow through the gaps between the rotor and stator. The refrigerant collects in the bottom of the motor casing and then drains
into the cooler through the motor cooling drain line.
The motor is protected by a temperature sensor and a
temperature switch imbedded in the stator windings. COMP
MOTOR WINDING TEMP temperatures above the COMP
MOTOR TEMP OVERRIDE threshold (see Capacity Override section, page 36) will override the chilled liquid temperature capacity control to hold. If the motor temperature rises
10° F (5.5 C) above this threshold, the compressor will unload.
If the COMP MOTOR WINDING TEMP rises above the
220 F (104.4 C) safety limit, the compressor will shut down.
Summary — The 23XRV requires an oil pump. Oil flow is
provided by a magnetically coupled, motor-driven oil pump.
Oil flows through the oil filter into the compressor rotors and
bearings. The cycle is referred to as a “high side” oil system.
See Fig. 8.
Details — The oil system:
•
lubricates the roller bearings which support the male
and female rotors, and the ball bearings of the 23XRV
compressor.
• lubricates the male and female rotors
Oil is charged into the system through a hand valve located
on the bottom of the oil sump. Sight glasses on the oil sump
permit oil level observation. When the compressor is shut
down, an oil level should be visible in the oil sump sight glass.
During operation, the oil level should always be visible in the
strainer housing sight glass. Approximately 7.5 gal. (28.4 L) of
oil is charged into the sump.
Oil from the compressor bearing drain is drained directly
into the oil sump. Refrigerant is driven from the oil as it flows
around the oil sump heater and into the strainer housing. The
oil pump draws the oil through a strainer and forces it through
an oil filter.
10
The oil sump contains temperature and pressure sensors and
a 530 W oil heater. The oil sump is vented to the compressor
suction to minimize the amount of refrigerant absorbed by the
oil. The OIL SUMP TEMPERATURE is measured and displayed on the ICVC default screen and the COMPRESS
screen. The oil sump pressure is used to calculate the OIL
PRESSURE DELTA P.
Operating OIL PRESSURE DELTA P must be at least
18 psid (124 kPa) after the OIL PRESS VERIFY TIME has
elapsed. Under normal full load conditions, oil pressure is
typically 20 to 28 psid (138 to 193 kPa). If sufficient oil pressure is not established or maintained the chiller will shut down.
An oil pressure delta P sensor fault will be declared if the OIL
PRESSURE DELTA P is not less than 4 psid (27.6 kPa) prior
to start-up.
The filter housing is capable of being isolated by upstream
and downstream valves to permit filter replacement. An oil
pressure regulator valve directs excessive oil back into the oil
sump. Oil supplied to the compressor is monitored by an oil
pressure sensor. The OIL PRESSURE DELTA P is equal to the
difference between the oil pressure leaving the filter and the oil
sump pressure. It is read directly from the ICVC (International
Chiller Visual Controller) default screen.
Oil is supplied to the compressor through two separate
inlets. One inlet leads to the suction bearings, the other leads to
the discharge bearings. Most of the oil drains back into the
sump while a small amount is used to lubricate the rotors.
Rotor lubrication oil leaves the compressor mixed with the
compressed discharge refrigerant vapor.
OIL SUPPLY
COMPRESSOR
TO COMPRESSOR
SUCTION
COMPRESSOR OIL
DRAIN
CONDENSER
ISOLATION
VALVE
COOLER
MIST
ELIMINATOR
ACTUATED BALL
VALVE
VAPORIZER
ORIFICE
SIGHT GLASS
EXTERNAL OIL HEATER
SIGHT GLASS
OIL
HEATER
OIL
SUMP
MIST ELIMINATOR
OIL PUMP
ISOLATION
VALVE
SIGHT GLASS
FILTER
ISOLATION SERVICE
VALVE
VALVE
PRESSURE
REGULATOR
VALVE
PUMP
STRAINER
a23-1623
OIL
REFRIGERANT
OIL FILTER
ISOLATION
VALVE
OIL/REFRIGERANT MIXTURE
Fig. 8 — Oil Flow Schematic
11
The PIC III controls respond to the difference between the
CONTROL POINT and LEAVING CHILLED LIQUID
temperatures when the ECL CONTROL OPTION is
DISABLED.
The PIC III controls respond to the difference between the
CONTROL POINT and ENTERING CHILLED LIQUID
temperatures when the ECL CONTROL OPTION is
ENABLED.
The chiller capacity is controlled by varying the TARGET
VFD SPEED from 0% to 100%. The PIC III controls monitor
the compressor oil properties and set a COMPRESSOR MINIMUM SPEED to ensure sufficient compressor bearing lubrication under all operating conditions.
If the oil pressure falls below the values specified in Table 1
during start-up, the PIC III control will shut down the chiller.
Table 1 — Oil Pressure Requirements
TIME
(SEC)
Before Oil Pump On
After Oil Press Verify Time
During Start/Run
MINIMUM START-UP OIL
PRESSURE REQUIREMENT
HFC-134a
PSID
kPaD
<4
27.6
18
124
15
103
Oil Reclaim System — The oil reclaim system recovers
oil from the cooler, removes the refrigerant, filters and returns
the oil back to the compressor. One or more oil reclaim nozzles
are positioned along the length of the cooler to draw the oil and
refrigerant mixture from the surface of the refrigerant level.
The mixture passes through an oil reclaim modulating valve
and into the vaporizer. The flow of refrigerant and oil is regulated to prevent the vaporizer from becoming overloaded with
liquid refrigerant. The modulating valve position is adjusted in
accordance with the difference between the VAPORIZER
TEMP and the EVAP REFRIG LIQUID TEMP. The 4 to 20
mA signal from CCM terminals J8-3 and J8-4 is converted into
a 0 to 10V DC input to the oil reclaim modulating valve by a
500 ohm resistor connected between CCM terminals J8-3 and
J8-4. The oil reclaim modulating valve closes when the chiller
is shut down to prevent the vaporizer and oil sump from being
flooded with refrigerant. Do not manually open the oil reclaim
modulating valve when the chiller is shut down. Doing so will
severely degrade the viscosity of the oil in the sump. Flow of
refrigerant and oil from the cooler can be observed through a
sight glass on top of the vaporizer.
The viscosity of the compressor oil is significantly reduced
when it absorbs refrigerant. A combination of heat and low
pressure is used to vaporize the refrigerant that has been
absorbed by the oil mixture reclaimed from the cooler.
Condenser gas is used to warm the refrigerant and oil mixture
in the vaporizer. Warm refrigerant is bled from the top of the
condenser, directed through a row of tubes that line the bottom
of the vaporizer, and discharged into the cooler. A 1500 W
surface mounted electric heater provides supplemental heat to
the vaporizer when the compressor is operating at lower loads.
Refrigerant boiled out of the reclaimed mixture is vented to the
compressor suction. The concentrated oil mixture drains out of
the vaporizer, through a sightglass, past the vaporizer temperature sensor, and into the oil sump. A 530 W oil sump heater
maintains the temperature of the reclaimed oil and the oil
returned from the compressor at approximately 90 F (32.2 C)
when the chiller is running and 140 F (60 C) when the chiller is
off. The oil sump is also vented to compressor suction to
increase oil viscosity by boiling off additional refrigerant.
CONTROLS
Definitions
ANALOG SIGNAL — An analog signal varies in proportion
to the monitored source. It quantifies values between operating
limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature,
generating many values.)
DISCRETE SIGNAL — A discrete signal is a two-position
representation of the value of a monitored source. (Example: A
switch produces a discrete signal indicating whether a value is
above or below a set point or boundary by generating an on/off,
high/low, or open/closed signal.)
General Controls Overview — The 23XRV hermetic
screw liquid chiller contains a microprocessor-based control
center that monitors and controls all operations of the chiller.
The microprocessor control system matches the cooling
capacity of the chiller to the cooling load while providing
state-of-the-art chiller protection. The system controls cooling
capacity within the set point plus the deadband by sensing the
leaving chilled liquid or brine temperature (see Fig. 9 and 10)
and regulating the compressor speed. Reducing the compressor
speed decreases the volume flow rate of refrigerant through the
compressor. Chiller protection is provided by the PIC III
processor, which monitors the digital and analog inputs and
executes capacity overrides or safety shutdowns, if required.
PIC III System Components (Fig. 11-14) — The
chiller control system is called PIC III (Product Integrated
Control III). See Table 2. The PIC III controls the chiller by
monitoring all operating conditions. The PIC III can diagnose a
problem and let the operator know what the problem is and
what to check. It promptly adjusts compressor speed to maintain leaving chilled liquid temperature. It can interface with
auxiliary equipment such as pumps and cooling tower fans to
turn them on when required. It continually checks all safeties to
prevent any unsafe operating condition. It also regulates the oil
heater and regulates the hot gas bypass valve, if installed. The
PIC III controls provide critical protection for the compressor
motor and control of the variable frequency drive.
The PIC III can interface with the Carrier Comfort
Network® (CCN) system if desired. It can communicate with
other PIC I, PIC II or PIC III equipped chillers and other CCN
devices, such as LEI (Local Equipment Interface).
Capacity Control — The PIC III controls provide chilled
liquid temperature control by modulating the frequency of the
power delivered by the VFD to the compressor motor. The
compressor speed is adjusted in response to the difference between the CONTROL POINT and the LEAVING CHILLED
LIQUID or ENTERING CHILLED LIQUID temperatures.
12
INTERNATIONAL CHILLER VISUAL CONTROLLER
(ICVC) — The ICVC is the “brain” of the PIC III. This
module contains all the primary software needed to control the
chiller. The ICVC is the input center for all local chiller set
points, schedules, configurable functions, and options.
The ICVC has a stop button, an alarm light, four buttons for
logic inputs, and a backlight display. The backlight will
automatically turn off after 15 minutes of non-use. The functions of the four buttons or “softkeys” are menu driven and are
shown on the display directly above the softkeys. The ICVC is
mounted on the Control Center door. See Fig. 2.
To change the contrast of the display, access the adjustment
on the back of the ICVC. See Fig. 11.
CHILLER CONTROL MODULE (CCM) — This module is
located on the control panel in the control center. The CCM
provides the input and outputs necessary to control the chiller.
This module monitors refrigerant pressure, entering and
leaving liquid temperatures and pressures, and outputs control
for the oil reclaim valve, oil heaters, and oil pump. The CCM is
the connection point for optional demand limit, automatic
chilled liquid reset, 4 to 20 mA kW output, remote temperature
reset, and refrigerant leak sensor.
VFD POWER MODULE — This module is located in the
control center (see Fig. 12). The A/C line I/O assembly executes commands from the ICVC for functions such as starting
and stopping the condenser and evaporator liquid pumps, tower
fan and alarm contacts. The Standard I/O Option Assembly
monitors inputs such as remote start contact, spare safety, and
high condenser pressure switch and provides the 4-20 mA
Head Pressure Reference Output.
VFD GATEWAY MODULE — The VFD Gateway Module
translates the protocols between the ICVC, CCM and VFD.
This module also contains logic capable of an independent
safety shutdown. It shuts down the chiller if communications
with the ICVC are lost. See Fig. 13 for power module component locations.
OIL HEATER CONTACTOR (1C) — This contactor is located on the control panel (Fig. 14) and operates the heater at
115 V. It is controlled by the PIC III to maintain oil temperature
during chiller shutdown.
OIL PUMP CONTACTOR (2C) — This contactor is located
in the control panel (Fig. 14) and operates the oil pump. The oil
pump is controlled by the PIC III to provide oil pressure during
pre-lube when the chiller is starting or running.
HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional) — This relay, located in the power panel, controls
the opening of the hot gas bypass valve. The PIC III energizes
the relay based on hot gas bypass algorithm settings.
VFD REFRIGERANT COOLING SOLENOID VALVE
(5C) — This solenoid is located on the VFD cooling line. The
VFD cooling solenoid regulates the amount of time refrigerant
is allowed to flow through the VFD cold plate to keep its
temperature within operating limits.
VAPORIZER HEATER CONTACTOR (6C) — This contactor is located in the control panel (Fig. 14) and energizes the
surface mounted heater on the bottom of the vaporizer.
CONTROL TRANSFORMERS (T1, T2) — These transformers convert incoming control voltage to 24 vac power for the
power panel contactor relays, CCM, ICVC, and 21 vac power
for the optional DataLINK™ or DataPort™ modules. Circuit
breakers CB-1A, CB-1B, CB-2A and CB-2B for the control
transformers are located above the CCM.
SHRINK WRAP
STRAIN RELIEF
1/8” NPT
THERMOWELL
REMOVABLE
TEMPERATURE
SENSOR
a23-1624
Fig. 9 — Control Sensors (Temperature)
a19-957
Fig. 10 — Control Sensors
(Pressure Transducers)
CONTRAST
ADJUSTMENT
SCREW
a23-1625
Fig. 11 — ICVC Contrast Adjustment
The PIC III controls are housed inside the control center
enclosure. See Fig. 14. The component names are listed
below (also see Table 2):
Table 2 — Major PIC III Components and
Panel Locations
PIC III COMPONENT
International Chiller Visual Controller
(ICVC) and Display
VFD Power Module
Chiller Control Module (CCM)
Oil Heater Contactor (1C)
Oil Pump Contactor (2C)
Hot Gas Bypass Relay (3C) (Optional)
Control Transformers (T1, T2)
Control Transformer Circuit Breakers
(CB-1A, CB-1B, CB-2A, CB-2B)
Temperature Sensors
Pressure Transducers
Vaporizer Heater Contactor (6C)
PANEL LOCATION
Control Center
Panel Door
Inside Control Center
Control Panel
Control Panel
Control Panel
Control Panel
Control Panel
Control Panel
See Fig. 3 and 9
See Fig. 3 and 10
Control Panel
13
10
21
11
20
1
2
9
8
13
5
8
22
FUSE
REF
FU1
FU2
FU3
FU4
FU5
FU6
FU7
FU8
FU9
FU10
FU11A&B
A2–F1
19
18
17
a23-1626
1
2
3
4
5
6
7
8
9
10
11
—
—
—
—
—
—
—
—
—
—
—
16
16
8
14
12
15
3
Input Inductor Assembly
Capacitor Bank Assembly
Pre-Charge Resistor Assembly
AC Contactor (3)
Power Module Assembly
Terminal Block, 10-Position (Extra low voltage)
Power Module Assembly
Fuse Block, 30A, 600V, Class CC
Fuse, Class CC, 600V, 15A (2)
7
4
12
13
14
15
16
17
18
19
20
21
22
—
—
—
—
—
—
—
—
—
—
—
FUSE
DESCRIPTION
Class CC, 1A/600V
Class CC, 1A/600V
Class CC, 1A/600V
150A/600V
150A/600V
150A/600V
Class CC, 20A/600V
Class CC, 20A/600V
Class CC, 20A/600V
Class CC, 5A/600V
Class CC, 15A/600V
3AG SLO–BLO
6
Transformer, 3kVA
Line Sync PC Board Assembly
Line Sync Board Cover
Fan, 115V (3)
Control Power Circuit Breaker, 600V, 15A
Circuit Breaker, 600V
Lug, Ground, 2-600 MCM
Inductor Overtemperature Switch (Hidden)
Input Power Wiring Access Panel
Terminal Block (Hazardous voltage)
Fig. 12 — Control Center VFD Input Components
1
2
5
3
16
4
6
20
23
7
8
25
17
9
10
18
11
26
6
7
25
20
24
3
19
8
12
10
4
21
11 8
1
13
22
14
15
a23-1627
Door Closed
Door Open
1
2
3
4
5
6
7
8
9
10
11
12
13
—
—
—
—
—
—
—
—
—
—
—
—
—
Wire Harness Assembly, Gate Driver
Current Feedback Device, 1000 A
Wire Harness Assembly, Power Supply, Logic
80 W Power Supply Assembly
Terminal Block, 2-Position
Cable Assembly, 40-Pin
Cable Assembly, 30-Pin
Wire Harness Assembly, Power Supply, Upper Gate
Inverter Power Interface Assembly
Wire Harness Assembly, Power Supply, Lower Gate
Insulation Sheet
Rectifier Power Interface Assembly
Wire Harness Assembly, Current Feedback Device
14
15
16
17
18
19
20
21
22
23
24
25
26
—
—
—
—
—
—
—
—
—
—
—
—
—
Wire Harness Assembly, DC Bus Bleeder Resistors
Wire Harness Assembly, Line Sync
Inverter Control Assembly*
Standard I/O Option, 24 V Assembly
Rectifier Control Assembly*
AC Line I/O Assembly
Connector, Terminal Block, 32-Pin
NTC Assembly
Internal Fan
DPI Communications Interface Assembly
RS-485 Communications Assembly (VFD Gateway)
Wire Harness Assembly, Control Sync
Cable Assembly, 20-pin
*The inverter control assembly (item 16) and rectifier control assembly (item 18) are physically similar but are loaded with different software.
These boards are NOT interchangeable.
Fig. 13 — Power Module Components
14
PRIMARY STATUS
MESSAGE
HAZARDOUS
VOLTAGE
FIELD WIRING
TERMINAL BLOCK
GROUND
WIRE
SECONDARY
STATUS
MESSAGE
VAPORIZER
HEATER
CONTACTOR (6C)
CONNECTOR
CNB
CONTINUOUSLY
• BLINKS
ON FOR AN ALARM
BLINKS
TO
• CONFIRMONCE
A STOP
HOT GAS
BYPASS
CONTACTOR (3C)
(OPTIONAL)
OIL PUMP
CONTACTOR
(2C)
24V
CONTROL
TRANSFORMER
(T1)
OIL HEATER
CONTACTOR
(1C)
CHL IN
58.4
CDL IN
CDL OUT
76.1
85.2
OIL PRESS
OILTEMP
–0.5
STATUS
11-22-04 00:09
15.2 HOURS
CHL OUT
59.3
130.6
SCHEDULE
TIME
SETPOINT
EVAP REF
62.1
COND REF
84.4
% AMPS IN
0.0
SERVICE
STOP BUTTON
FOR ONE
• HOLD
SECOND TO STOP
20V CONTROL
TRANSFORMER
(T2)
SOFT KEYS
CONTROL
TRANSFORMER
CIRCUIT
BREAKERS
EACH KEY'S FUNCTION IS
DEFINED BY THE MENU DESCRIPTION
ON MENU LINE ABOVE
a23-1600
MENU
LINE
Fig. 15 — ICVC Default Screen
HIGH
PRESSURE
SWITCH
CABLE
CONNECTOR
CN2
SERVICE
23XRPIC3
ALARM HISTORY
ALERT HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
VFD CONFIG DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
ICVC CONFIGURATION
CONNECTOR
CN3
a23-1628
DATE
MANUALLY STOPPED - PRESS
CCN OR LOCAL TO START
ALARM LIGHT
(ILLUMINATED
WHEN POWER ON)
CONNECTOR
CN1A
COMPRESSOR
ON TIME
LOW VOLTAGE
FIELD WIRING
TERMINAL BLOCK
Fig. 14 — Control Panel
ICVC Operation and Menus (Fig. 15-21)
GENERAL
• The ICVC display automatically reverts to the default
screen after 15 minutes if no softkey activity takes place
(Fig. 15).
• If a screen other than the default screen is displayed on the
ICVC, the name of that screen is in the upper right corner
(Fig. 16).
• The ICVC may be set to display either English or SI units.
Use the ICVC CONFIGURATION screen (accessed from
the SERVICE menu) to change the units. See the Service
Operation section, page 45.
• Local Operation — The PIC III can be placed in local
operating mode by pressing the LOCAL softkey. The
PIC III then accepts commands from the ICVC only and
uses the Local Time Schedule to determine chiller start
and stop times.
• CCN Operation — The PIC III can be placed in the
CCN operating mode by pressing the CCN softkey.
The PIC III then accepts modifications from any CCN
interface or module (with the proper authority), as well
as from the ICVC. The PIC III uses the CCN Time
Schedule to determine start and stop times.
a23-1601
Fig. 16 — ICVC Service Screen
ALARMS AND ALERTS — An alarm shuts down the compressor. An alert does not shut down the compressor, but it
notifies the operator that an unusual condition has occurred. An
alarm (*) or alert (!) is indicated in the STATUS column on the
right side of the MAINSTAT display screen. See Fig. 17.
Alarms are indicated when the control center alarm light (!)
flashes. The primary alarm message is displayed on the default
screen. An additional, secondary message and troubleshooting
information are sent to the ALARM HISTORY screen.
When an alarm is detected, the ICVC default screen will
freeze (stop updating) at the time of alarm. The freeze enables
the operator to view the chiller conditions at the time of alarm.
Additional information is stored in the VFD_HIST screen. The
STATUS tables will show the updated information. Once all
alarms have been cleared (by pressing the RESET softkey),
the default ICVC screen will return to normal operation.
15
23XRPIC3
MAINSTAT
Control Mode
Run Status
Start Inhibit Timer
Occupied?
System Alert/Alarm
Chiller Start/Stop
Remote Start Contact
Temperature Reset
Control Point
Chilled Liquid Temp
•
Press ENTER to leave the selected decision or field and
save changes.
•
Press NEXT to scroll the cursor bar down in order to
highlight a point or to view more points below the current screen.
•
Press PREVIOUS to scroll the cursor bar up in order to
highlight a point or to view points above the current
screen.
•
Press SELECT to view the next screen level (highlighted with the cursor bar), or to override (if allowable)
the highlighted point value.
•
Press EXIT to return to the previous screen level.
•
Press INCREASE or DECREASE to change the highlighted point value.
POINT STATUS
Reset
Tripout
0.0 min
No
Alarm
Stop CONTRL
Open
C
0.0 ^F
50.0 °F
55.7 °F
a23-1602
Fig. 17 — Example of MAINSTAT Screen
ICVC MENU ITEMS — To perform any of the operations
described below, the PIC III must be powered up and have
successfully completed its self test. The self test takes place
automatically, after power-up.
Press the MENU softkey to view the list of menu structures: STATUS , SCHEDULE , SETPOINT , and
SERVICE .
• The STATUS menu allows viewing and limited calibration or modification of control points and sensors, relays
and contacts, and the options board.
• The SCHEDULE menu allows viewing and modification of the local and CCN Time Schedules.
• The SETPOINT menu allows set point adjustments,
such as the ENTERING CHILLED LIQUID and LEAVING CHILLED LIQUID set points.
• The SERVICE menu can be used to view or modify
information on the ALARM HISTORY, ALERT HISTORY, CONTROL TEST, CONTROL ALGORITHM
STATUS, EQUIPMENT CONFIGURATION, VFD
CONFIG DATA, EQUIPMENT SERVICE, TIME
AND DATE, ATTACH TO NETWORK DEVICE,
LOG OUT OF DEVICE, AND ICVC CONFIGURATION screens.
For more information on the menu structures, refer to
Fig. 18.
Press the softkey that corresponds to the menu structure to
be viewed: STATUS , SCHEDULE , SETPOINT , or
SERVICE . To view or access parameters within any of these
menu structures, use the NEXT and PREVIOUS softkeys
to scroll to the desired item or table. Use the SELECT softkey to select that item. The softkey choices that then appear depend on the selected table or menu. The softkey choices and
their functions are described below.
TO VIEW STATUS (Fig. 17) — The MAINSTAT table
shows the actual value of overall chiller status such as CONTROL MODE, RUN STATUS, AUTO CHILLED LIQ
RESET, and REMOTE RESET SENSOR.
1. On the menu screen, press STATUS to view the list
of point status tables.
BASIC ICVC OPERATIONS (Using the Softkeys) — To
perform any of the operations described below, the PIC III
must be powered up and have successfully completed its self
test.
• Press QUIT to leave the selected decision or field without saving any changes.
16
For Discrete Points — Press YES
select the desired state.
2. Press NEXT or PREVIOUS to highlight the desired
status table. The list of tables is:
• MAINSTAT — Overall chiller status
• STARTUP — Status required to perform start-up of
chiller
• COMPRESS — Status of sensors related to the
compressor
• HEAT_EX — Status of sensors related to the heat
exchangers
• POWER — Status of motor input power
• VFD_STAT — Status of the variable frequency
drive
• ICVC_PSWD — Service menu password forcing
access screen
YES
NO
or
ENTER
NO
to
EXIT
For Analog Points — Press INCREASE
DECREASE to select the desired value.
or
3. Press ENTER to register the new value.
3. Press SELECT to view the desired point status table.
NOTE: When overriding or changing metric values, it is necessary to hold down the softkey for a few seconds in order to
see a value change, especially on kilopascal values.
To Remove an Override
1. On the point status table press NEXT
or
to
highlight
the
desired
value.
PREVIOUS
4. On the point status table, press NEXT or
PREVIOUS until the desired point is displayed on the
screen.
2. Press SELECT to access the highlighted value.
OVERRIDE OPERATIONS
To Override a Value or Status
1. From any point status screen, press NEXT
PREVIOUS to highlight the desired value.
or
3. Press RELEASE to remove the override and return
the point to the PIC III’s automatic control.
2. Press SELECT to select the highlighted value. Then:
Override Indication — An override value is indicated by
“SUPVSR,” “SERVC,” or “BEST” flashing next to the point
value on the STATUS table.
17
DEFAULT SCREEN
LOCAL
CCN
RESET
MENU
(SOFTKEYS)
Start Chiller In CCN Control
Start Chiller in Local Control
Clear Alarms
Access Main Menu
STATUS
SCHEDULE
SETPOINT
1 1 1 1 (ENTER A 4-DIGIT PASSWORD)
List the
Status Tables
List the Service Tables
Display The Setpoint Table
• MAINSTAT
• STARTUP
• COMPRESS
• HEAT_EX
• POWER
• VFD_STAT
• ICVC_PWD
Select a Status Table
PREVIOUS
NEXT
Select a Modification Point
PREVIOUS
NEXT
Modify a Discrete Point
START
STOP
ON
OFF
Modify an Analog Point
INCREASE DECREASE
Modify Control Options
DISABLE
ENABLE
SERVICE
List the Schedules
EXIT
• Base Demand Limit
• LCL Setpoint
• ECL Setpoint
• Ice Build Setpoint
• Tower Fan High Setpoint
Select the Setpoint
SELECT
PREVIOUS
NEXT
SELECT
EXIT
Modify the Setpoint
INCREASE DECREASE
RELEASE
ENTER
RELEASE
ENTER
QUIT
ENTER
SELECT
QUIT
EXIT
ENTER
• OCCPC01S – LOCAL TIME SCHEDULE
• OCCPC02S – ICE BUILD TIME SCHEDULE
• OCCPC03S – CCN TIME SCHEDULE
Select a Schedule
SELECT
PREVIOUS
EXIT
NEXT
1
2
3
4
5
6
7
8
Override
Select a Time Period/Override
SELECT
PREVIOUS
NEXT
EXIT
Modify a Schedule Time
INCREASE DECREASE
ENTER
EXIT
(ANALOG VALUES)
Add/Eliminate a Day
ENABLE
DISABLE
ENTER
EXIT
(DISCRETE VALUES)
NEXT
ALARM HISTORY
ALERT HISTORY
CONTROL TEST
VFD CONFIG DATA
EQUIPMENT SERVICE
TIME AND DATE
LOG OUT OF DEVICE
ICVC CONFIGURATION
SELECT
PREVIOUS
EXIT
SEE FIGURE 19
a23-1603
Fig. 18 — 23XRV ICVC Menu Structure
18
SERVICE TABLE
NEXT
PREVIOUS
SELECT
EXIT
ALARM HISTORY
ALERT HISTORY
ALERT HISTORY
Display Alert History
(The table holds up to 25 alerts
with the most recent alert
at the top of the screen.)
Display Alarm History
(The table holds up to 25 alarms and
alerts with the most recent alarm
at the top of the screen.)
CONTROL TEST
List the Control Tests
• Thermistors
• Pressure Transducers
• Pumps
• Discrete Outputs
• Oil Reclaim Output
• Head Pressure Output
• Pumpdown/Lockout
• Terminate Lockout
List the Control Algorithm Status Tables
• CAPACITY (Capacity Control)
• OVERRIDE (Override Status)
• LL_MAINT (Lead Lag Status)
• VFD_HIST (VFD Alarm History)
• CUR ALRM (Chiller Alarm History)
• WSMCHLRE (Water System Manager)
• OCCDEFCM (Time Schedule Status)
Select a Table
SELECT
PREVIOUS
NEXT
Select a Test
NEXT
PREVIOUS
SELECT
EXIT
EXIT
OCCDEFM (Time Schedule Status)
Data Select Table
PREVIOUS
NEXT
SELECT
• CAPACITY (Capacity Control Algorithm)
• OVERRIDE (Override Status)
• LL_MAINT (LEADLAG Status)
• WSMDEFME (Water System Manager Control Status)
EXIT
OCCPC01S (Local Status)
OCCPC02S (CCN, ICE BUILD Status)
OCCPC03S (CCN Status)
Maintenance Table Data
List the Equipment Configuration Tables
• NET_OPT
• BRODEF
• OCCEFCS
• HOLIDAYS
• CONSUME
• RUNTIME
Select a Table
PREVIOUS
NEXT
EXIT
Select a Parameter
PREVIOUS
NEXT
SELECT
EXIT
Modify a Parameter
INCREASE DECREASE
QUIT
ENTER
(ANALOG VALUES)
QUIT
ENTER
(DISCRETE VALUES)
ENABLE
CONTINUED
ON NEXT PAGE
SELECT
DISABLE
a23-1604
Fig. 19 — 23XRV Service Menu Structure
19
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
VFD CONFIG DATA
EQUIPMENT SERVICE
4 4 4 4 (ENTER A 4-DIGIT PASSWORD)
Service Tables:
• OPTIONS
• SETUP1
• SETUP2
• LEADLAG
• RAMP_DEM
• TEMP_CTL
Select a Service Table
PREVIOUS
NEXT
Service Tables:
• VFD CONFIG P ASSWORD
• VFD_CONF
SELECT
EXIT
Select a Service Table Parameter
SELECT
PREVIOUS
NEXT
EXIT
Modify a Service Table Parameter
INCREASE DECREASE
QUIT
ENABLE
DISABLE
QUIT
ENTER
(ANALOG VALUES)
ENTER
(DISCRETE VALUES)
TIME AND DATE
Display Time and Date Table:
• To Modify — Current Time
— Current Date
INCREASE DECREASE
ENTER
List Network Devices
• Device 6
• Local
• Device 1 • Device 7
• Device 2 • Device 8
• Device 3 • Attach To Any Device
• Device 4
• Device 5
Select a Device
PREVIOUS
NEXT
SELECT
YES
NO
ENTER
— Day of Week
— Holiday Today
(ANALOG VALUES)
EXIT
EXIT
(DISCRETE VALUES)
ATTACH
Modify Device Address
INCREASE DECREASE
ENTER
EXIT
• Use to attach ICVC to another CCN network or device
• Attach to "LOCAL" to enter this machine
• To upload new tables
LOG OUT OF DEVICE
Default Screen
LOCAL
CCN
RESET
MENU
ICVC CONFIGURATION
CCN
ICVC
—
—
IMP
—
VFD —
PIC III —
LEGEND
Carrier Comfort Network®
International Chiller Visual
Controller
Imperial
Product Integrated Control III
ICVC Configuration Table
INCREASE DECREASE
ENTER
EXIT
• To View — ICVC Software Version
• To Modify — ICVC CCN Address
(last 2 digits of part number
— Baud Rate
indicate software version)
— English (US IMP) or S.I. Metric Units
— Password
a23-1605
— LID Language
Fig. 19 — 23XRV Service Menu Structure (cont)
20
TIME SCHEDULE OPERATION (Fig. 20)
1. On the Menu screen, press SCHEDULE .
b. Press ENABLE to select days in the day-of-week
fields. Press DISABLE to eliminate days from the
period.
2. Press NEXT or PREVIOUS to highlight the desired schedule.
7. Press ENTER to register the values and to move horizontally (left to right) within a period.
OCCPC01S — LOCAL Time Schedule
OCCPC02S — ICE Build Schedule
OCCPC03S — CCN Time Schedule
8. Press EXIT to leave the period or override.
3. Press SELECT to view the desired time schedule.
9. Either return to Step 4 to select another period or override, or press EXIT again to leave the current time
schedule screen and save the changes.
4. Press NEXT or PREVIOUS to highlight the desired period or override to change.
10. The Holiday Designation (HOLIDAYS table) may be
found in the Service Operation section, page 45. The
month, day, and duration for the holiday must be
assigned. The TIME BROADCAST ENABLE function in the BRODEF screen also must be enabled for
holiday periods to function.
TO VIEW AND CHANGE SET POINTS (Fig. 21)
1. To view the SETPOINT table, from the MENU screen
press SETPOINT .
5. Press SELECT to access the highlighted period or
override.
6. a Press INCREASE or DECREASE to change the
time values. Override values are in one-hour
increments, up to 4 hours.
23XRPIC3
SETPOINT
Base Demand Limit
Control Point Source
LCL Setpoint
ECL Setpoint
Ice Build Setpoint
Tower Fan High Setpoint
23XRPIC3
SETPOINT SELECT
100%
50.0 °F
60.0 °F
40.0 °F
75 °F
a23-1607
Fig. 21 — Example of Set Point Screen
a23-1606
Fig. 20 — Example of Time Schedule
Operation Screen
21
5. Press INCREASE or DECREASE to change the
selected set point value.
2. There are 5 set points on this screen: BASE DEMAND
LIMIT, LCL SETPOINT (leaving chilled liquid set
point), ECL SETPOINT (entering chilled liquid set
point), ICE BUILD SETPOINT and TOWER FAN
HIGH SETPOINT. Only one of the CONTROL
POINT SOURCES (LCL or ECL) can be active at one
time. The control point source that is active is determined from the TEMP_CTL screen. See the Service
Operation section, page 45.
3. Press NEXT or PREVIOUS to highlight the desired
set point entry.
6. Press ENTER to save the changes and return to the
previous screen.
SERVICE OPERATION — To view the menu-driven programs available for Service Operation, see Service Operation
section, page 45. For examples of ICVC display screens, see
Table 3.
4. Press SELECT to modify the highlighted set point.
Table 3 — ICVC Display Data
by the CCN, BSI, LEI, and the ICVC. Capitalized Reference Point
Names preceded by two asterisks can be changed only from the
ICVC. Reference Point Names in lower case type can be viewed by
CCN or BSI only by viewing the whole table.
7. Alarms and Alerts: An asterisk in the far right field of a ICVC status
screen indicates that the chiller is in an alarm state; an exclamation
point in the far right field of the ICVC screen indicates an alert state.
The asterisk (or exclamation point) indicates that the value on that
line has exceeded (or is approaching) a limit. For more information on
alarms and alerts, see the Alarms and Alerts section, page 15.
8. Index of all ICVC Parameters is shown in Appendix A.
IMPORTANT: The following notes apply to all Table 3 examples.
1. Only 12 lines of information appear on the ICVC screen at any one
time. Press the NEXT or PREVIOUS softkey to highlight a point
or to view items below or above the current screen. Double-click the
NEXT softkey to page forward; double-click the PREVIOUS
softkey to page back.
2. To access the information shown in Examples 9 through 23, enter
your 4-digit password after pressing the SERVICE softkey. If no
softkeys are pressed for 15 minutes, the ICVC automatically logs off
(to prevent unrestricted access to PIC III controls) and reverts to the
default screen. If this happens, you must re-enter your password to
access the tables shown in Examples 9 through 23.
1CR
CCN
CHL
CR
CT
I2T
ICVC
ECL
HGBP
LCL
LRA
mA
P
T
VFD
WSM
°F
ˆF
3. Terms in the Description column of these tables are listed as they
appear on the ICVC screen.
4. The ICVC may be configured in English or Metric (SI) units using the
ICVC CONFIGURATION screen. See the Service Operation section,
page 45, for instructions on making this change.
5. The items in the Reference Point Name column do not appear on the
ICVC screen. They are data or variable names used in CCN, Building
Systems Interface (BSI) or Local Equipment Interface (LEI) Module
software (optional). They are listed in these tables as a convenience
to the operator if it is necessary to cross reference CCN/BSI documentation or use CCN/BSI programs. For more information, see the
CCN literature.
6. Reference Point Names shown in these tables in all capital letters
can be read by CCN and BSI software. Of these capitalized names,
those preceded by a dagger can also be changed (that is, written to)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
LEGEND
Control Relay
Carrier Comfort Network®
Chilled Liquid
Control Relay
Current Transformer
Motor Overload
Entering Chilled Liquid
Hot Gas Bypass
Leaving Chilled Liquid
Locked Rotor Amps
Milliamps
Pressure
Temperature
Liquid System Manager
Temperature in Degrees Fahrenheit
Temperature Difference in Degrees Fahrenheit
EXAMPLE 1 — ICVC DEFAULT SCREEN
The following data is displayed in the ICVC Default screen.
DESCRIPTION
(PRIMARY MESSAGE)
(SECONDARY MESSAGE)
(DATE AND TIME)
Compressor Ontime
Evaporator Refrigerant Temperature*
Entering Condenser Liquid
Leaving Condenser Liquid
Condenser Refrigerant Temperature
Oil Pressure Delta P
Oil Sump Temp
Percent Line Current
CCN
LOCAL
RESET
RANGE
0-500000.0
–40-245
–40-245
–40-245
–40-245
–40-245
–40-245
–6.7-425
–40-245
0-999
0-1
0-1
0-1
UNITS
HOURS
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
PSI (kPa)
°F (°C)
%
REFERENCE POINT NAME
(ALARM HISTORY)
C_HRS
ECL
LCL
ERT_EST
ECDL
LCDL
CRT
OIL_PD
OILT
AMPS_P
CCN
LOCAL
RESET
*The Evaporator Refrigerant Temperature displayed is the smaller value of EVAP REFRIG LIQUID TEMP or CALC EVAP SAT TEMP.
NOTE: The last three entries are used to indicate operating mode to the PIC III. These values may be forced by the ICVC only.
22
DISPLAY
CHL IN
CHL OUT
EVAP REF
CDL IN
CDL OUT
COND REF
OILPRESS
OIL TEMP
% AMPS IN
Table 3 — ICVC Display Data (cont)
EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN
To access this display from the ICVC default screen:
1. Press MENU .
2. Press STATUS ( MAINSTAT will be highlighted).
3. Press SELECT .
DESCRIPTION
Control Mode
Run Status
Start Inhibit Timer
Occupied ?
System Alert/Alarm
*Chiller Start/Stop
*Remote Start Contact
Temperature Reset
*Control Point
Chilled Liquid Temp
*Active Demand Limit
Percent Line Kilowatts
Auto Demand Limit Input
Auto Chilled Liq Reset
Remote Reset Sensor
†Total Compressor Starts
Starts in 12 Hours
†Compressor Ontime
**Service Ontime
Ice Build Contact
Refrigerant Leak Sensor PPM
Emergency Stop
STATUS
NOTE 2
NOTE 3
0-15
0/1
0-2
0/1
0/1
–30-30
10-65
–40-245
40-100
0.0-9999
0.0-9999
4-20
4-20
–40-245
0-99999
0-8
0-500000.0
0-32767.0
0/1
0.0-9999.0
0/1
UNITS
NOTE 2
NOTE 3
min
NO/YES
NOTE 4
STOP/START
OPEN/CLOSE
^ F (^ C)
° F (° C)
° F (° C)
%
%
%
mA
mA
° F (°C)
HOURS
HOURS
OPEN/CLOSE
mA
ENABLE/EMSTOP
POINT
MODE
STATUS
T_START
OCC
SYS_ALM
CHIL_S_S
REMCON
T_RESET
LCW_STPT
CHL_TMP
DEM_LIM
LN AMPS_P
LINE KW_P
AUTODEM
AUTORES
R_RESET
C_STARTS
STARTS
C_HRS
S_HRS
ICE_CON
REF_LEAK
EMSTOP
NOTES:
1. Numbers in parentheses indicate the equivalent CCN BEST++™ programming LEI or BACnet™ Translator use.
2. Off (0), Local (1), CCN (2), Reset (3)
3. Timeout (0), Ready (1), Recycle (2), Startup (3), Running (4), Demand (5), Ramping (6), Auto Restart (7), Override (8), Tripout (9), Control Test
(10), Lockout (11), Pumpdown (12), Prestart (13)
4. Normal (0), Alert (1), Alarm (2).
5. All variables with capital letter point names are available for CCN read operation.
Those shown with (*) support write operations for all CCN and LEI devices.
Those shown with (†) shall support one time write operations for the ICVC only when the value is initially zero.
Those shown with (**) shall support write operations for the ICVC only.
EXAMPLE 3 — STARTUP DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight STARTUP .
4. Press SELECT .
DESCRIPTION
**Chilled Liquid Pump
Chilled Liquid Flow
**Condenser Liquid Pump
Condenser Liquid Flow
Oil Pump Relay
Oil Reclaim Output
**Oil Pressure Delta P
Oil Sump Temp
Vaporizer Temp
VFD Start
Start Complete
Stop Complete
VFD Speed Output
Comp Motor RPM
Comp Motor Frequency
Comp Maximum Speed
Comp Minimum Speed
**Tower Fan Relay Low
**Tower Fan Relay High
Spare Safety Input
Shunt Trip Relay
STATUS
0-1
0-1
0-1
0-1
0-1
0-100.0
–6.7-200
–40.0-245.0
–40.0-245.0
0-1
0-1
0-1
0.0-100.0
0-300000
0-10000
0-101
0-100
0-1
0-1
0-1
0-1
UNITS
OFF/ON
NO/YES
OFF/ON
NO/YES
OFF/ON
%(4 to 20mA)
PSI (kPa)
° F (° C)
° F (° C)
NO/YES
FALSE/TRUE
FALSE/TRUE
%
RPM
Hz
Hz
%
OFF/ON
OFF/ON
ALARM/NORMAL
OFF/ON
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
Those shown with (**) shall support write operations for the ICVC only.
23
POINT
CHLP
CHL_FLOW
CDP
CDL_FLOW
OILR
OIL_MA
OILPD
OILT
VAP_TEMP
VFDSTART
START_OK
STOP_OK
VFD_OUT
CPR_RPM
VFD_FREQ
MAXSPEED
MINSPEED
TFR_LOW
TFR_HIGH
SAFETY
TRIPR
EXAMPLE 4 — COMPRESS DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight COMPRESS .
4. Press SELECT .
DESCRIPTION
Actual VFD Speed
Compressor Motor RPM
Compressor Motor Frequency
Compressor Maximum Speed
Compressor Minimum Speed
VFD Delta
**Target VFD Speed
VFD Speed Output
Oil Pump Relay
**Oil Pressure Delta P
Oil Sump Temp
Vaporizer Temperature
Oil Heater Relay
Vaporizer Heater
Comp Motor Winding Temp
Comp Discharge Temp
Discharge Superheat
Stall Protection Counts
Spare Temperature 1
Spare Temperature 2
STATUS
0-115
0-300000
0-10000
0-101
0-100
–2-2
0-100
0-100
0/1
–6.7-420
–40-245
–40-245
0/1
0/1
–40-245
–40-245
–20-999
0-5
–40-245
–40-245
UNITS
%
RPM
Hz
Hz
%
%
%
%
OFF/ON
PSI (kPa)
° F (° C)
° F (° C)
OFF/ON
OFF/ON
° F (° C)
° F (° C)
^F (^C)
° F (° C)
° F (° C)
POINT
VFD_ACT
CPR_RPM
VFD_FREQ
MAXSPEED
MINSPEED
VFDDELTA
VFD_TRG
VFD_OUT
OILR
OILPD
OILT
VAP_TEMP
OILHEAT
VAP_HEAT
MTRW
CMPD
SUPRHEAT
SPC
SPARE_T1
SPARE_T2
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;
those with (**) shall support write operations for ICVC only.
EXAMPLE 5 — HEAT_EX DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight HEAT_EX .
4. Press SELECT .
DESCRIPTION
**Chilled Liquid Delta P
Chilled Liquid Delta T
Chill Liq Pulldown/Min
Calc Evap Sat Temp
**Evaporator Pressure
Evap Refrig Liquid Temp
Evaporator Approach
**Condenser Liquid Delta P
Entering Cond Liquid
Leaving Cond Liquid
Condenser Refrig Temp
**Condenser Pressure
Condenser Approach
Vaporizer Temp
Reclaim Delta T
Oil Reclaim Output
VFD Coolant Flow
Hot Gas Bypass Relay
Active Delta P
Active Delta T
HGBP Delta T
Head Pressure Reference
STATUS
–6.7-420
–40-245
–40-245
–40-245
–20-20
–40-245
–6.7-420
–40-245
0-99
–6.7-420
–40-245
–40-245
–40-245
–6.7-420
0-99
–40-245
–500-500
0-100
0-100
0/1
0-200
0-200
0-200
0-100
UNITS
PSI (kPa)
° F (° C)
° F (° C)
^F (^C)
^F (^C)
° F (° C)
PSI (kPa)
° F (° C)
^F (^C)
PSI (kPa)
° F (° C)
° F (° C)
° F (° C)
PSI (kPa)
^F (^C)
° F (° C)
^F (^C)
%
%
OFF/ON
PSI (kPa)
^F (^C)
^F (^C)
%
those with (**) shall support write operations for ICVC only.
24
POINT
CHLPD
ECL
LCL
CHL_DT
CHL_PULL
ERT
ERP
EST
EVAP_APP
CDLPD
ECDL
LCDL
CRT
CRP
COND_APP
VAP_TEMP
R_DELTA
OIL_MA
VFD_FOUT
HGBYPASS
DP_A
DT_A
DT_C
HPR
EXAMPLE 6 — POWER DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight POWER .
4. Press SELECT .
DESCRIPTION
Average Line Current
Percent Line Voltage
Average Line Voltage
Line Power Factor
Line Kilowatts
Percent Load Current
Average Load Current
Motor Power Factor
Motor Kilowatts
Percent Motor Kilowatts
Motor Kilowatt-Hours
Demand Kilowatts
Line Current Phase 1 (R)
Line Current Phase 2 (S)
Line Current Phase 3 (T)
Load Current Phase 1 (U)
Load Current Phase 2 (V)
Load Current Phase 3 (W)
Line Voltage Phase 1 (RS)
Line Voltage Phase 2 (ST)
Line Voltage Phase 3 (TR)
Ground Fault Current
Line Frequency
Rectifier Overload
Inverter Overload
Motor Overload
Line Current Imbalance
Motor Current Imbalance
Line Voltage Imbalance
Line Active Current
Line Reactive Current
Line Active Voltage
Line Reactive Voltage
DC Bus Voltage Reference
DC Bus Voltage
Flux Current
Torque Current
Inverter Temperature
Rectifier Temperature
VFD Enclosure Temperature
VFD Cold Plate Temperature
Humidity Sensor Input
Relative Humidity
VFD Coolant Flow
Actual VFD Speed
Comp Motor RPM
Comp Maximum Speed
Comp Minimum Speed
STATUS
0-999
0-99999
0-999
0-99999
0.0-2.0
0-99999
0-99999
0-99999
0-99999
0.0-2.0
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-999
0-99
0-100
0-100
0-100
0-100
0-100
0-100
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-300
0-300
0-300
0-300
0.0-5.0
0-100
0-100
0-100
0-300000
0-10000
0-101
0-100
UNITS
%
AMPS
%
VOLTS
KW
%
%
AMPS
KW
%
KWH
KW
AMPS
AMPS
AMPS
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
HZ
%
%
%
%
%
%
AMPS
AMPS
VOLTS
VOLTS
VOLTS
VOLTS
AMPS
AMPS
° F (° C)
° F (° C)
° F (° C)
° F (° C)
VOLTS
%
%
%
RPM
Hz
Hz
%
25
POINT
LNAMPS_P
LNAMPS_A
LNVOLT_P
LNVOLT_A
LINE_PF
LINE_KW
LINEKW_P
LDAMPS_P
LDAMPS_A
MOTOR_PF
MOTOR_KW
MOTORKWP
MOTORKWH
DEM_KW
LN_AMPS1
LN_AMPS2
LN_AMPS3
LD_AMPS1
LD_AMPS2
LD_AMPS3
LN_VOLT1
LN_VOLT2
LN_VOLT3
GF_AMPS
LINEFREQ
RECT_OV
INV_OV
MOTOR_OV
LN_IMB_I
MT_IMB_I
LN_IMB_V
AMPS_ACT
AMPS_RE
VOLT_ACT
VOLT_RE
BUS_REF
BUS_VOLT
FLUXAMPS
TORQAMPS
INV_TEMP
REC_TEMP
VFD_ENCL
CP_TEMP
HUMID_SR
HUMIDITY
VFD_FOUT
VFD_ACT
CPR_RPM
VFD_FREQ
MAXSPEED
MINSPEED
EXAMPLE 7 — VFD
VFD_STAT SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight VFD_STAT .
4. Press SELECT .
DESCRIPTION
VFD Fault Code
Single Cycle Dropout
Line Phase Reversal
High Line Voltage
Low Line Voltage
High DC Bus Voltage
Low DC Bus Voltage
Motor Overload
Rectifier Overcurrent
Rectifier Overtemp
Rectifier Power Fault
Inverter Overcurrent
Inverter Overtemp
Inverter Power Fault
Ground Fault
Frequency Fault
VFD Power on Reset
Start Complete
Stop Complete
Condenser High Pressure
Motor Amps Not Sensed
Start Acceleration Fault
Stop Fault
VFD Start Inhibit
VFD Checksum Error
VFD Comm Fault
VFD Fault
VFD Gateway Version #
VFD Inverter Version #
VFD Rectifier Version #
STATUS
0-272
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-255
0-1000
0-1000
UNITS
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
FALSE/TRUE
FALSE/TRUE
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
POINT
VFD_FLT
CYCLE_1
LINEIM_I
LINEIM_V
PH_REV
HI_VOLT
LOW_VOLT
HI_DCBUS
LO_DCBUS
MOTIM_I
MOTOR_OV
RECT_OI
RECT_OT
RECT_PU
INV_OI
INV_OT
INV_PU
GRND_FLT
FREQFLT
VFD_POR
START_OK
STOP_OK
PRS_TRIP
NO_AMPS
ACCELFLT
AMPSTOP
STRT_INH
CHECKSUM
VFD_COMM
VFDFAULT
VFG_VER
INV_VER
REC_VER
EXAMPLE 8 — ICVC PWD
1. Press MENU .
2. Press STATUS
3. Scroll down to highlight ICVC_PWD .
DESCRIPTION
Disable Service Password
**Remote Reset Option
Reset Alarm ?
CCN Mode ?
STATUS
0-1
0-1
0-1
0-1
UNITS
DS/ENABLE
DS/ENABLE
NO/YES
NO/YES
POINT
PSWD_DIS
RESETOPT
REMRESET
REM_CCN
NOTE: The Disable Service Password parameter supports the service tool password disable access. It will only allow forcing with the service tool
for a one time bypass of both the service menu and the VFD config data table. Exit from the service menu reverts to normal password operation.
Those with (**) shall support write operations for ICVC only.
The Reset Alarm? and CCN mode? parameters support write operations from CCN and LEI devices when the Remote Reset Option is enabled.
26
EXAMPLE 9 — SETPOINT DISPLAY SCREEN
1. Press MENU .
2. Press SETPOINT (Base Demand Limit will be highlighted).
3. Press SELECT .
DESCRIPTION
Base Demand Limit
LCL Setpoint
ECL Setpoint
Ice Build Setpoint
STATUS
40-100
UNITS
%
POINT
DLM
DEFAULT
100
10-60 F (-12.2-15.6 C)
15-65 F (-9.4-18.3 C)
15-60 F (-9.4-15.6 C)
55-105 F (13-41 C)
° F (° C)
° F (° C)
° F (° C)
° F (° C)
lcl_sp
ecl_sp
ice_sp
TFH_sp
50.0 F (10.0 C)
60.0 F (15.6 C)
40 F (4.4 C)
75 F (23.9 C)
NOTE: No variables are available for CCN read operation; forcing shall not be supported on setpoint screens.
EXAMPLE 10 — CAPACITY DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight CAPACITY .
DESCRIPTION
Capacity Control
Control Point
Control Point Error
ECL Delta T
ECL Reset
LCL Reset
Total Error + Resets
Cap Delta
VFD Delta
Target VFD Speed
Actual VFD Speed
Comp Motor RPM
Comp Maximum Speed
Comp Minimum Speed
VFD Speed Output
VFD Gain
Demand Limit Inhibit
Amps/kW Ramp
STATUS
–40-245
–40-245
UNITS
° F (°C)
° F (°C)
POINT
ECL
LCL
10-65
–99-99
–99-99
–99-99
–99-99
–99-99
–2-2
–2-2
0-100
0-110
0-300000
0-10000
0-101
0-100
0-110
0.1-1.5
0.2-1
0-100
° F (°C)
^F (^C)
^F (^C)
^F (^C)
^F (^C)
^F (^C)
%
%
%
%
RPM
Hz
Hz
%
%
ctrlpt
cperr
ecldt
eclres
lclres
error
capdelta
vfddelta
VFD_TRG
VFD_ACT
CPR_RPM
VFD_FREQ
MAXSPEED
MINSPEED
VFD_OUT
vfd_gain
DEM_INH
RAMP_LMT
%
%
forcing shall not be supported on maintenance screens.
27
EXAMPLE 11 — OVERRIDE DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight OVERRIDE .
DESCRIPTION
Comp Motor Temp Override
Condenser Pressure
Cond Press Override
Calc Evap Sat Temp
Evap Sat Override Temp
Comp Discharge Temp
Comp Discharge Alert
Rectifier Temp Override
Inverter Temp Override
Discharge Superheat
STATUS
–40-245
150-200
–6.7-420
150-260
–40-245
2-45
–40-245
125-200
0-300
125-200
0-300
125-200
–20-999
–40-245
UNITS
° F (°C)
° F (°C)
PSI (kPa)
PSI (kPa)
° F (°C)
° F (°C)
° F (°C)
° F (°C)
° F (°C)
° F (°C)
° F (°C)
° F (°C)
^F (^C)
° F (°C)
POINT
MTRW
MT_OVER
CRP
CP_OVER
ERT
ERT_OVER
CMPD
CD_ALERT
RECT_TEMP
REC_OVER
INV_TEMP
INV_OVER
SUPRHEAT
CRT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on
maintenance screens.
EXAMPLE 12 — LL_MAINT DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight LL_MAINT .
DESCRIPTION
Lead Lag Control
LEADLAG: Configuration
Current Mode
Load Balance Option
LAG Start Time
LAG Stop Time
Prestart Fault Time
Pulldown Time
Pulldown: Delta T/Min
Satisfied ?
LEAD CHILLER in Control
LAG CHILLER: Mode
Run Status
Start/Stop
Recovery Start Request
STANDBY CHILLER: Mode
Run Status
Start/Stop
Recovery Start Request
Spare Temperature 1
Spare Temperature 2
STATUS
NOTE 1
NOTE 1
NOTE 2
0/1
0-60
0-60
0-60
0.0-30.0
XX.X
0/1
0/1
NOTE 3
NOTE 4
NOTE 5
0/1
NOTE 3
NOTE 4
NOTE 5
0/1
–40-245
–40-245
UNITS
DSABLE/ENABLE
MIN
MIN
MIN
MIN
^F (^C)
NO/YES
NO/YES
NO/YES
NO/YES
° F (°C)
° F (°C)
POINT
leadlag
llmode
loadbal
lagstart
lagstop
preflt
pulltime
pull_dt
pull_sat
leadctrl
lagmode
lagstat
lag_s_s
lag_rec
stdmode
stdstat
std_s_s
std_rec
SPARE_T1
SPARE_T2
NOTES:
1. DISABLE, LEAD, LAG, STANDBY, INVALID
2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG
3. Reset, Off, Local, CCN, Blank
4. Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout, ‘Blank’
5. Stop, Start, Retain, ‘Blank’
6. All variables with CAPITAL LETTER point names are available for CCN read operation;
28
EXAMPLE 13 — VFD_HIST DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight VFD_HIST .
DESCRIPTION
VFD FAULT HISTORY
Values At Last Fault:
Line Current Phase 1 (R)
Line Current Phase 2 (S)
Line Current Phase 3 (T)
Load Current Phase 1 (U)
Load Current Phase 2 (V)
Load Current Phase 3 (W)
Line Voltage Phase 1 (RS)
Line Voltage Phase 2 (ST)
Line Voltage Phase 3 (TR)
Line Frequency
Line Power Factor
Motor Power Factor
Motor Overload
Line Active Current
Line Active Voltage
DC Bus Voltage
Flux Current
Torque Current
VFD Enclosure Temp
VFD Cold Plate Temp
Actual VFD Speed
Comp Motor RPM
Chiller Fault State
VFD Fault Code
STATUS
UNITS
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-999
0-99
0-2.0
0-100
0-100
0-2.0
0-100
0-100
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
AMPS
AMPS
AMPS
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
Hz
%
%
%
%
AMPS
AMPS
VOLTS
VOLTS
VOLTS
VOLTS
0-99999
0-99999
0-300
0-300
0-300
0-300
0-100
0-300000
0-10000
200-272
200-272
AMPS
AMPS
° F (°C)
° F (°C)
° F (°C)
° F (°C)
%
RPM
Hz
POINT
LNAMPS1H
LNAMPS2H
LNAMPS3H
LDAMPS1H
LDAMPS2H
LDAMPS3H
LNVOLT1H
LNVOLT2H
LNVOLT3H
GF_AMPSH
LINEFRQH
LINE_PFH
LN_IMBIH
LN_IMBVH
MOTORPFH
MT_IMBIH
MOTOROVH
AMPSACTH
AMPS_REH
VOLTACTH
VOLT_REH
BUSVOLTH
BUS_REFH
FLUXAMPH
TORQAMPH
INVTEMPH
RECTEMPH
VFDENCLH
CP_TEMPH
VFD_ACTH
CPR_RPMH
VFDFREQH
VFDSTATH
VFD_FLTH
EXAMPLE 14 — LOADSHED DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight LOADSHED .
DESCRIPTION
LOADSHED FUNCTION
Redline
Loadshed
Loadshed Timer
STATUS
UNITS
0-1
0-1
0-480
NO/YES
NO/YES
29
POINT
REDLINE
LOADSHED
LOADTIME
EXAMPLE 15 — WSMCHLRE DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight WSMDEFME .
DESCRIPTION
WSM Active?
Chilled Water Temp
Equipment Status
Commanded State
CHW Setpoint Reset Value
Current CHW Set Point
STATUS
0/1
0.0-99.9
0/1
UNITS
NO/YES
° F (°C)
OFF/ON
TEXT
^ F (^C)
° F (°C)
0.0-25.0
0.0-99.9
POINT
WSMSTAT
CHWTEMP
CHWRST
CHWRENA
CHWRVAL
CHWSTPT
EXAMPLE 16 — NET_OPT DISPLAY SCREEN
1. Press MENU .
2.
3.
4.
5.
Press SERVICE .
Scroll down to highlight EQUIPMENT CONFIGURATION .
Press SELECT .
Scroll down to highlight NET_OPT .
DESCRIPTION
Loadshed Function
Group Number
Demand Limit Decrease
Maximum Loadshed Time
CCN Occupancy Config:
Schedule Number
Broadcast Option
Alarm Configuration
Re-Alarm Time
Alarm Routing
STATUS
UNITS
POINT
DEFAULT
1-16
0-60
30-480
%
MIN
LDSGRPN
LDSDLTA
MAXSHED
0
20
120
3-99
0-1
DSABLE/ENABLE
OCC_NUM
OCCBRCST
3
DSABLE
RETIME
ROUTING
30
10000000
0-1440
0-1
MIN
NOTE: No variables are available for CCN read or write operation.
30
EXAMPLE 17 — VFD_CONF DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight VFD CONFIG DATA .
4. Press SELECT .
5. Scroll down to highlight VFD_CONF .
DESCRIPTION
Motor Nameplate Voltage
Compressor 100% Speed
* Rated Line Voltage
* Rated Line Amps
* Rated Line Kilowatts
*Motor Rated Load KW
*Motor Rated Load Amps
Motor Nameplate Amps
Motor Nameplate RPM
Motor Nameplate kW
Inverter PWM Frequency
(0=4 kHz, 1=2 kHz)
Skip Frequency 1
Skip Frequency 2
Skip Frequency 3
Skip Frequency Band
Line Voltage % Imbalance
Line Voltage Imbal Time
Line Current % Imbalance
Line Current Imbal Time
Motor Current % Imbalance
Motor Current Imbal Time
Increase Ramp Time
Decrease Ramp Time
STATUS
480-480
54-101
346-480
10-5000
0-999999
0-999999
10-5000
10-5000
1500-3030
0-999999
0/1
UNITS
VOLTS
Hz
VOLTS
AMPS
KW
KW
AMPS
AMPS
0-102
0-102
0-102
0-102
1-10
1-10
5-40
1-10
5-40
1-10
5-60
5-60
0/1
Hz
Hz
Hz
Hz
%
SEC
%
SEC
%
SEC
SEC
SEC
DSABLE/ENABLE
KW
POINT
motor_nv
comp_100
vfd_volt
vfd_amps
vfd_rlkw
mot_rlkw
mot_rla
motorni
motorpm
motorkw
pwm_freq
DEFAULT
480
70
460
200
100
100
200
100
2672
100
0
skipfrq1
skipfrq2
skipfrq3
skipband
v_umbal
v_time
lineim_i
lineim_t
motim_i
motim_t
ramp_inc
ramp_dec
cycdrop
102
102
102
0
10
10
40
10
40
10
30
30
DSABLE
NOTE: Those parameters marked with a * shall not be downloaded to the VFD, but shall be used in other calculations and algorithms in the ICVC.
EXAMPLE 18 — OPTIONS DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE .
4. Press SELECT .
5. Scroll down to highlight OPTIONS .
DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
Hot Gas Bypass
HGBP Option
Min. Load Point (T1,P1)
HGBP Delta T1
HGBP Delta P1
Full Load Point (T2,P2)
HGBP Delta T2
HGBP Delta P2
HGBP Deadband
HGBP On Delta T
HGBP Off Delta T
Stall Protection
Stall Delta % Amps
Stall Time Period
Ice Build Control
Ice Build Option
Ice Build Termination
(0=TEMP, 1=Contact, 2=Both)
Ice Build Recycle
Refrigerant Leak Option
PPM at 20mA
Refrig Leak Alarm PPM
Delta P at 0% (4mA)
Delta P at 100% (20mA)
Minimum Output
STATUS
0/1
0/1
40-100
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
POINT
astart
r_contac
softstop
0, 1, 2
0=DSABLE
1=HGBP
2=LOW LOAD
HGBP
Srg_hgbp
DSABLE
0.5-20 (0.3-11.1)
10-170 (68.9-1172.2)
^F (^C)
PSI (kPa)
hgbp_dt1
hgbp_dp1
1.5 (0.8)
150 (1034.2)
0.5-20 (0.3-11.1)
30-250 (206.9-1724)
0.5-3 (0.3-1.7)
0.5-10.0 (0.3-5.6)
1.0-10.0 (0.6-5.6)
^F (^C)
PSI (kPa)
^F (^C)
^F (^C)
^F (^C)
hbgp_dt2
hgbp_dp2
hbgp_db
hgb_ton
hgb-toff
4 (2.2)
200 (1379)
1 (0.6)
2.0 (1.17)
4.0 (2.2)
5-20
7-10
%
MIN
stall_a
stall_t
10
8
0/1
0-2
DSABLE/ENABLE
ibopt
ibterm
DSABLE
0
0/1
0/1
0-99999
0-99999
DSABLE/ENABLE
DSABLE/ENABLE
ibrecyc
LEAK_EN
PPM_20
PPM_LIM
DSABLE
DSABLE
1000
500
20-85 (138-586)
20-85 (138-586)
0-100
PSI (kPa)
PSI (kPa)
%
HPDP0
HPDP100
HPDPMIN%
25 (172)
50 (241)
0
31
DEFAULT
DSABLE
DSABLE
100
EXAMPLE 19 — SETUP1 DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight SETUP1 .
DESCRIPTION
Cond Press Override
STATUS
150-200 (66-93)
145-166 (1000-1145)
125-160 (52-71)
155-170 (68-77)
155-170 (68-77)
UNITS
° F (°C)
PSI (kPa)
° F (°C)
° F (°C)
° F (°C)
POINT
MT_OVER
CP_OVER
CD_ALERT
REC_OVER
INV_OVER
DEFAULT
200 (93)
145 (1000)
140 (60)
160 (71)
160 (71)
Chilled Medium
Chilled Liquid Deadband
Evap Refrig Trippoint
Refrig Override Delta T
Evap Approach Alert
Cond Approach Alert
Condenser Freeze Point
0/1
0.5-2.0 (0.3-1.1)
10-40.0 (-12.2-4.4)
2.0-5.0 (1.1-2.8)
0.5-15 (0.3-8.3)
0.5-15 (0.3-8.3)
–20 -35 ( -28.9-1.7)
WATER/BRINE
^F (^C)
° F (°C)
^F (^C)
^F (^C)
^F (^C)
° F (°C)
MEDIUM
CLDB
ERT_TRIP
REF_OVER
EVAP_AL
CDAP_AL
CDFREEZE
WATER
1.0 (0.6)
33 (0.6)
3 (1.7)
5 (2.8)
6 (3.3)
34 (1.1)
Flow Delta P Display
Evap Flow Delta P Cutout
Cond Flow Delta P Cutout
Oil Press Verify Time
Liquid Flow Verify Time
0/1
0.5 - 50.0 (3.45-344.7)
0.5 - 50.0 (3.45-344.7)
15-300
0.5-5
DS/ENABLE
PSI (kPa)
PSI (kPa)
SEC
MIN
FLOWDISP
EVAP_CUT
COND_CUT
oilpr_t
LFLOW_T
DSABLE
5.0 (34.5)
5.0 (34.5)
45
5
Recycle Control
Restart Delta T
Shutdown Delta T
2.0-10.0 (1.1-5.6)
0.5-4.0 (.28-2.2)
^F (^C)
^F (^C)
rcycr_dt
rcycs_dt
5 (2.8)
1 (0.6)
sp1_en
sp1_lim
sp2_ en
sp2_ lim
0
245 (118)
0
245 (118)
Spare Alert/Alarm Enable
Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable
Spare Temp #1 Limit
Spare Temp #2 Limit
0-4
–40-245 (-40-118)
0-4
–40-245 (-40-118)
° F (°C)
° F (°C)
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
EXAMPLE 20 — SETUP2 DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight SETUP2 .
DESCRIPTION
Capacity Control
Proportional Inc Band
Proportional Dec Band
Proportional ECL Gain
VFD Speed Control
VFD Gain
VFD Minimum Speed
VFD Maximum Speed
Vaporizer Heater Mode
0=Normal, 1=Service
STATUS
UNITS
2-10
2-10
1-3
0.1-1.5
15-50
50-100
0/1
%
%
POINT
DEFAULT
vfd_inc
vfd_dec
vfd_ecl
6.5
6.0
2
vfd_gain
vfd_min
vfd_max
vhtr_mode
0.75
20
100
0
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
32
EXAMPLE 21 — LEAD/LAG DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight LEADLAG .
DESCRIPTION
Lead Lag Control
LEAD/LAG Configuration
DSABLE=0, Lead=1
LAG=2, STANDBY=3
Load Balance Option
Common Sensor Option
LAG % Capacity
LAG Address
LAG START Timer
LAG STOP Timer
PRESTART FAULT Timer
PULLDOWN Timer
STANDBY Chiller Option
STANDBY % Capacity
STANDBY Address
STATUS
UNITS
POINT
0-3
0/1
0/1
25-75
1-236
2-60
2-60
2-30
1-30
0/1
25-75
1-236
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
MIN
DSABLE/ENABLE
%
DEFAULT
leadlag
0
loadbal
commsens
lag_per
lag_add
lagstart
lagstop
preflt
pulldown
stnd_opt
stnd_per
stnd_add
DSABLE
DSABLE
50
92
10
10
5
2
DSABLE
50
93
EXAMPLE 22 — RAMP_DEM DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight RAMP_DEM .
DESCRIPTION
Pulldown Ramp Type:
Select: Temp=0, KW=1
Demand Limit and kW Ramp
Demand Limit Source
Select: Amps=0, kW=1
Amps or kW Ramp %/Min
Demand Limit Prop Band
Demand Limit At 20 mA
20 mA Demand Limit Opt
Demand Watts Interval
STATUS
0/1
UNITS
0/1
5-20
3-15
40-100
0/1
5-60
%
%
DSABLE/ENABLE
MIN
POINT
ramp_opt
DEFAULT
1
dem_src
0
kw_ramp
dem_app
dem_20ma
dem_sel
dw_int
10
10
40
DSABLE
15
EXAMPLE 23 — TEMP_CTL DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight TEMP_CTL .
DESCRIPTION
ECL Control Option
Temp Pulldown Ramp/Min
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA
RESET TYPE 2
Remote Temp –> No Reset
Remote Temp –> Full Reset
Degrees Reset
RESET TYPE 3
CHL Delta T –> No Reset
CHL Delta T –> Full Reset
Degrees Reset
Enable Reset Type
STATUS
UNITS
POINT
DEFAULT
0/1
2-10 (1.1-5.6)
DSABLE/ENABLE
^F (^C)
ecl_opt
tmp_ramp
DSABLE
3 (1.7)
–30- 30 (-17-17)
^F (^C)
deg_20ma
10 (6)
–40-245 (-40-118)
–40-245 (-40-118)
–30-30 (-17-17)
° F (°C)
° F (°C)
^F (^C)
res_rt1
res_rt2
deg_rt
85 (29)
65 (18)
10 (6)
0-15 (0-8)
0-15 (0-8)
–30-30 (-17-17)
^F (^C)
^F (^C)
^F (^C)
restd_1
restd_2
deg_res
10 (6)
0 (0)
5 (3)
res_sel
0
0-3
33
PIC III System Functions
Table 4 — Capacity Control Conditions
NOTE: Words not part of paragraph headings and printed in all
capital letters can be viewed on the ICVC (e.g., LOCAL,
CCN, RUNNING, ALARM, etc.) Words printed in both all
capital letters and italics can also be viewed on the ICVC and
are parameters (CONTROL MODE ADDED EXAMPLES,
etc.) with associated values (e.g., modes, temperatures, pressures, percentages, on, off, enable, disable, etc.).Words printed
in all capital letters and in a box represent softkeys on the
ICVC (e.g., ENTER and EXIT ). See Table 3 for examples of
the type of information that can appear on the ICVC screens.
Figures 15-21 give an overview of ICVC operations and
menus. The sequence of screens that should be selected to
view any parameter in the ICVC can be found in Appendix A.
Capacity
DELTA
TARGET VFD
Forced
Increase
X
Decrease
X
VFD Speed
= Min.
VFD Speed
= Max
Increase
X
Increase
Decrease
Decrease
•
X
VFD SPEED
CHANGE
TARGET VFD
= Forced Value
TARGET VFD
= Forced Value
TARGET VFD
= TARGET VFD +
(VFD Delta *
VFD Gain)
No Change
No Change
TARGET VFD
= TARGET VFD +
(VFD Delta *
VFD Gain)
VFD DELTA less than 0.2% will not cause the VFD
SPEED OUTPUT to increase or decrease.
• If the Capacity Decrease is in effect due to an override
then the VFD SPEED OUTPUT decreases at a rate of
2.0% per 5 seconds until the decrease condition is satisfied. This will occur regardless of VFD DELTA value.
• A VFD SPEED OUT OF RANGE fault will be declared
if the ACTUAL VFD SPEED exceeds the VFD SPEED
OUTPUT ±10% for 75 seconds when the chiller is
running.
• A COMP MIN SPEED LIMITED RUN CAPACITY
OVERRIDE alert will be declared when the TARGET
VFD SPEED is being limited by the COMPRESSOR
MINIMUM SPEED.
ECL CONTROL OPTION — If this option is enabled, the
PIC III modulates the compressor speed in response to the
entering chilled liquid temperature instead of the LEAVING
CHILLED LIQUID temperature. The ECL CONTROL
OPTION may be viewed on the TEMP_CTL screen, which is
accessed from the EQUIPMENT SERVICE screen.
CHILLED LIQUID DEADBAND — This is the tolerance
range on the chilled liquid/brine temperature control point. If
the liquid temperature goes outside the CHILLED LIQUID
DEADBAND, the PIC III increases or decreases compressor
speed until the temperature is within tolerance. The PIC III
may be configured with a 0.5 to 2 F (0.3 to 1.1 C) deadband.
CHILLED LIQUID DEADBAND may be viewed or modified
on the SETUP1 screen, which is accessed from the EQUIPMENT SERVICE table.
Example: A 1º F (0.6º C) CHILLED LIQUID DEADBAND setting controls the liquid temperature within ±0.5º F
(0.3º C) of the CONTROL POINT. This may cause frequent
changes in compressor speed if the cooling load fluctuates
frequently. A value of 1º F (0.6º C) is the default setting.
PROPORTIONAL BANDS AND PROPORTIONAL
GAIN — The PIC III uses the PROPORTIONAL INC
(Increase) BAND, PROPORTIONAL DEC (Decrease) BAND,
and the PROPORTIONAL ECL (Entering Chilled Liquid)
GAIN to determine how fast or slow to respond. Proportional
band is the rate at which the compressor speed is changed in
proportion to how far the chilled liquid/brine temperature is
from the CONTROL POINT. Proportional gain determines
how quickly the VFD reacts to how quickly the temperature is
deviating from the CONTROL POINT. The proportional bands
and proportional gain may be viewed or modified from the
SETUP2 screen, which is accessed from the EQUIPMENT
SERVICE table.
The Proportional Band — The PIC III controls can be configured to respond differently to temperature deviations above the
control point and to temperature deviations below the control
point.
CAPACITY CONTROL — The PIC III controls the chiller
capacity by changing the compressor speed in response to
chilled liquid temperature deviation away from the CONTROL
POINT. The CONTROL POINT may be changed by a CCN
network device or is calculated by the PIC III adding any active
chilled liquid reset to the ECL or LCL SET POINT. The
CONTROL POINT may be viewed or overridden from the
MAINSTAT screen. See page 23.
Changes to the chiller capacity and system overrides are
achieved through the VFD SPEED OUTPUT.
The VFD SPEED OUTPUT is controlled by varying the
output from 0 to 100%. The TARGET VFD SPEED is forcible
and allows the operator manual control of the VFD SPEED
OUTPUT. The TARGET VFD SPEED will be allowed to
change every five seconds unless TARGET VFD SPEED is
forced.
The TARGET VFD SPEED is controlled between the VFD
MINIMUM SPEED and VFD MAXIMUM SPEED (refer to
SETUP2 screen) based on the Capacity Control algorithm. The
PIC III controls monitor the compressor oil properties and set a
COMPRESSOR MINIMUM SPEED to ensure sufficient compressor bearing lubrication under all operating conditions. The
TARGET VFD SPEED shall not be allowed to be forced below the COMP MINIMUM SPEED. A summary of all capacity control conditions and responses is shown in Table 4.
Changes to the VFD SPEED are implemented by the
following methods:
FORCED — The TARGET VFD SPEED can be forced from
the ICVC. The TARGET VFD SPEED is set to the forced
value and remains there until the force is removed or the chiller
is shut down. The forced value is limited between the VFD
MINIMUM SPEED and VFD MAXIMUM SPEED.
NORMAL CONDITIONS — VFD speed changes are based
on the calculated change in VFD DELTA multiplied by the
VFD GAIN. VFD DELTA is displayed in the COMPRESS
screen. The VFD GAIN increases or decreases the commanded
VFD speed change with respect to the VFD DELTA calculated
by the ICVC.
CAPACITY INCREASE — If the TARGET VFD SPEED is
less than the VFD MAXIMUM SPEED, the TARGET VFD
SPEED is increased by the VFD DELTA times the VFD
GAIN.
CAPACITY DECREASE — If the TARGET VFD SPEED
is greater than the VFD MINIMUM SPEED, the TARGET
VFD SPEED is decreased by the VFD DELTA times the VFD
GAIN.
34
to START. For more information on forced starts, see Local
Start-Up, page 46.
The schedules also can be overridden to keep the chiller in
an occupied state for up to 4 hours, on a one time basis. See the
Time Schedule Operation section, page 21.
Figure 20 shows a schedule for a typical office building
with a 3-hour, off-peak, cool-down period from midnight to
3 a.m., following a weekend shutdown. Holiday periods are in
an unoccupied state 24 hours per day. The building operates
Monday through Friday, 7:00 a.m. to 6:00 p.m., and Saturdays
from 6:00 a.m. to 1:00 p.m. This schedule also includes the
Monday midnight to 3:00 a.m. weekend cool-down schedule.
NOTE: This schedule is for illustration only and is not
intended to be a recommended schedule for chiller operation.
Whenever the chiller is in the LOCAL mode, it uses Occupancy Schedule 01 (OCCPC01S). The chiller uses Occupancy
Schedule 02 (OCCPCO2S) when it is in ICE BUILD mode.
When the chiller is in CCN mode, it uses Occupancy Schedule
03 (OCCPC03S).
The CCN SCHEDULE NUMBER is configured on the
NET_OPT display screen, accessed from the EQUIPMENT
CONFIGURATION table. See Table 3, Example 16. SCHEDULE NUMBER can be changed to any value from 03 to 99. If
this number is changed on the NET_OPT screen, the operator
must go to the ATTACH TO NETWORK DEVICE screen to
upload the new number into the SCHEDULE screen. See
Fig. 19.
The PIC III controls response to temperatures above the
control point is affected by the PROPORTIONAL INC BAND.
This parameter will slow or quicken the rate at which the compressor speed is changed in response to chilled liquid/brine
temperatures above the control point plus 1/2 times the
CHILLED LIQUID DEADBAND. The PROPORTIONAL INC
BAND can be adjusted from a setting of 2 to 10; the default
setting is 6.5. A smaller value of PROPORTIONAL INC
BAND will increase the rate at which the compressor speed is
increased.
The response below the control point is called the PROPORTIONAL DEC BAND, this parameter will slow or quicken
the rate at which the compressor speed is changed in response
to chilled liquid temperatures below the CONTROL POINT
minus 1/2 times the CHILLED LIQUID DEAD BAND. The
PROPORTIONAL DEC BAND can be adjusted on the ICVC
from a setting of 2 to 10. The default setting is 6.0. A smaller
value of PROPORTIONAL DEC BAND will increase the rate
at which the compressor speed is decreased.
The PROPORTIONAL ECL GAIN changes the amount the
compressor speed is changed each time the PIC III controls
command an adjustment. The PROPORTIONAL ECL GAIN
can be adjusted from 1 to 3. A larger value of PROPORTIONAL ECL GAIN will increase the amount the compressor speed
changes each time the controls call for a change.
DEMAND LIMITING — The PIC III responds to the
ACTIVE DEMAND LIMIT set point by limiting the amps or
kilowatts consumed by the chiller. It compares the ACTIVE
DEMAND LIMIT set point to the DEMAND LIMIT SOURCE
(either the actual AVERAGE LINE CURRENT or the actual
MOTOR KW), depending on how the control is configured.
DEMAND LIMIT SOURCE is on the RAMP_DEM screen.
The default DEMAND LIMIT SOURCE is the compressor
motor amps.
CHILLER TIMERS — The PIC III maintains 2 runtime
clocks, known as COMPRESSOR ONTIME and SERVICE
ONTIME. COMPRESSOR ONTIME indicates the total
life-time compressor run hours. This timer can register up to
500,000 hours before the clock turns back to zero. The
SERVICE ONTIME is a resettable timer that can be used to
indicate the hours since the last service visit or any other event.
The time can be changed from the ICVC to whatever value is
desired. The SERVICE ONTIME timer can register up to
32,767 hours before it rolls over to zero.
The chiller also maintains a start-to-start timer and a stopto-start timer. These timers limit how soon the chiller can be
started. START INHIBIT TIMER is displayed on the MAINSTAT screen. See the Start-Up/Shutdown/Recycle Sequence
section, page 46, for more information on this topic.
OCCUPANCY SCHEDULE — The chiller schedule, described in the Time Schedule Operation section (page 21),
determines when the chiller can run. Each schedule consists of
from 1 to 8 occupied or unoccupied time periods, set by the
operator. The chiller can be started and run during an occupied
time period (when YES is displayed next to OCCUPIED? on
the MAINSTAT display screen). It cannot be started or run
during an unoccupied time period (when NO is displayed next
to OCCUPIED ? on the MAINSTAT display screen). These
time periods can be set for each day of the week and for holidays. The day begins with 0000 hours and ends with
2400 hours. When any occupancy schedule is in a time period
when the chiller is allowed to run, the parameter OCCUPIED?
is YES.
These schedules can be set up to follow a building’s occupancy schedule, or can be set to be occupied 100% of the time,
if the operator wishes. In this case, the chiller is normally started and stopped manually using the CCN, LOCAL, and STOP
buttons. The schedules also can be bypassed by forcing the
CHILLER START/STOP parameter on the MAINSTAT screen
Safety Controls — The PIC III monitors all safety control inputs and, if required, shuts down the chiller or limits the
compressor speed to protect the chiller from possible damage
from any of the following conditions:
• high motor winding temperature
• high discharge temperature
• low oil pressure
• low evaporator refrigerant temperature
• condenser high pressure or low pressure
• inadequate liquid/brine cooler and condenser flow
• high, low, or loss of voltage
• ground fault
• voltage imbalance
• current imbalance
• excessive motor acceleration time
• lack of motor current signal
• excessive motor amps
• motor stall
• temperature sensor and transducer faults
• VFD power faults
• VFD over temperature
• humidity surrounding the VFD coldplate
• reverse compressor rotation
VFD faults or protective devices within the VFD can shut
down the chiller.
If compressor motor overload or a motor ground fault
occurs, check the motor for grounded or open phases
before attempting a restart.
If the PIC III control initiates a safety shutdown, it displays
the reason for the shutdown (the fault code) on the ICVC display screen along with a primary and secondary message, and
blinks the alarm light on the control center. The alarm is stored
in memory and can be viewed on the ALARM HISTORY and
VFD_HIST screens on the ICVC, along with a message for
troubleshooting. If the safety shutdown was also initiated by a
fault detected in the VFD, the conditions at the time of the fault
will be stored in VFD_HIST.
35
2. Motor load ramp loading (AMPS OR KW RAMP %/
MIN) limits the percent per minute rate at which the
compressor motor current or compressor motor load
increases. The AMPS OR KW RAMP %/MIN rate is
configured by the operator on the RAMP_DEM screen
in amps or kilowatts.
If kilowatts is selected for the DEMAND LIMIT SOURCE,
the MOTOR RATED LOAD KILOWATTS must be entered
(information found on the machine Electrical Data Nameplate)
in the VFD_CONF screen.
The TEMP PULLDOWN DEG/MIN may be viewed or
modified on the TEMP_CTL screen which is accessed from the
EQUIPMENT SERVICE screen. PULLDOWN RAMP TYPE,
DEMAND LIMIT SOURCE, and MOTOR KW RAMP %/MIN
may be viewed or modified on the RAMP_DEM screen.
Capacity Override (Table 6) — Adjustable capacity
overrides are available to prevent the chiller from exceeding
some limits and going into an alarm state. Alert messages 120
through 127 are displayed on the ICVC when capacity
overrides are in effect. Capacity overrides can prevent some
safety shutdowns caused by exceeding the refrigerant low
temperature safety limit, motor high temperature safety limit,
and condenser high pressure limit, high VFD inverter rectifier
temperature limit, and high VFD inverter temperature limit.
To give more precise information or warnings on the chiller’s operating condition, the operator can define alert limits on
various monitored inputs in the SETUP1 screen. Safety contact
and alert limits are defined in Table 5. Alarm and alert messages are listed in the Troubleshooting Guide section, page 81.
Shunt Trip — The function of the shunt trip on the PIC III
is to act as a safety trip. The shunt trip is wired from the standard I/O board to a shunt trip equipped VFD circuit breaker. If
the PIC III tries to shut down the compressor using a normal
shutdown procedure but is unsuccessful for 20 seconds, the
shunt trip output is energized and causes the circuit breaker to
trip off. The ground fault trip also will energize the shunt trip to
trip the circuit breaker. Protective devices in the VFD can also
energize the shunt trip. The shunt trip feature can be tested
using the Control Test feature in the DISCRETE OUTPUTS
CONTROL TEST screen. Reset the circuit breaker immediately after performing this test.
Default Screen Freeze — When the chiller is in an
alarm state, the default ICVC display “freezes,” that is, it stops
updating. The first line of the ICVC default screen displays a
primary alarm message; the second line displays a secondary
alarm message.
The ICVC default screen freezes to enable the operator to
see the conditions of the chiller at the time of the alarm. If the
value in alarm is one normally displayed on the default screen,
the value flashes between normal and reverse contrast. The
ICVC default screen remains frozen until the condition that
caused the alarm is remedied by the operator.
Knowledge of the operating state of the chiller at the time an
alarm occurs is useful when troubleshooting. Additional chiller
information can be viewed on the status screens and the
VFD_HIST screen. Troubleshooting information is recorded in
the ALARM HISTORY table, which can be accessed from the
SERVICE menu.
To determine what caused the alarm, the operator should
read both the primary and secondary default screen messages,
as well as the alarm history. The primary message indicates the
most recent alarm condition. The secondary message gives
more detail on the alarm condition. Since there may be more
than one alarm condition, another alarm message may appear
after the first condition is cleared. Check the ALARM HISTORY screen for additional help in determining the reasons for the
alarms. Once all existing alarms are cleared (by pressing the
RESET softkey), the default ICVC display returns to normal
operation.
Ramp Loading — The ramp loading feature controls the
rate at which the compressor loads up. This control can prevent
the compressor from loading up too fast during the short period
of time when the chiller is started and the chilled liquid loop
has to be brought down to the CONTROL POINT. This helps
reduce electrical demand charges by slowly bringing the
chilled liquid to the CONTROL POINT.
There are two methods of ramp loading with the PIC III.
Ramp loading can be based on chilled liquid temperature or on
motor load. The method of ramp loading is selected from the
RAMP__DEM screen.
1. Temperature ramp loading (TEMP PULLDOWN DEG/
MIN) limits the degrees per minute rate at which either
the leaving chilled liquid or the entering chilled liquid
temperature decreases. This rate is configured by the
operator on the TEMP_CTL screen. The lowest temperature ramp rate will be used if chiller power has
been off for 3 hours or more (even if the motor kilowatts ramp loading is selected as the ramp loading
method).
Compressor Minimum Speed Override — This
capacity override increases compressor speed if oil viscosity
falls below acceptable levels or if conditions exist that will
prevent sufficient refrigerant cooling to the VFD or motor. This
override is not configurable, it is the only override that will
increase chiller capacity to avoid a safety shutdown. Compressor minimum speed override is most likely to happen at
evaporator temperatures of 50 degrees or more, combined with
low speed, low lift, and less than 25% tons.
The PIC III controls regulate the minimum allowable compressor speed based on oil sump temperature and pressure and
on compressor head. The compressor bearings require higher
oil viscosity when operating at low speed than they do when
operating at high speeds. The controls increase compressor
speed when the oil viscosity is too low to operate the compressor at the lower speed. The low compressor speed override is
also enabled at low loads with high condensing pressure.
Vaporizer Temperature Control COMPRESSOR ON — The vaporizer temperature control is regulated
by the PIC III using the vaporizer heater relay and a flexible
surface heater that is attached to the bottom of the vaporizer.
The vaporizer heater relay is energized whenever the compressor is at low loads and requires additional heat to maintain a
sufficient vaporizer temperature. The vaporizer heater is turned
off when the additional heat is no longer required. The vaporizer heater is not energized when the chiller is not running.
Oil Sump Temperature Control COMPRESSOR OFF — The OIL SUMP TEMP is regulated by the
PIC III using the oil heater relay and an immersion heater in the
oil sump. The oil heater relay is energized whenever the chiller
compressor is off, and the OIL SUMP TEMP is less than 140 F
(60 C) or whenever the OIL SUMP TEMP is less than the
CALC EVAP SAT TEMP plus 53 F (29.4 C). The oil heater is
then turned off when the OIL SUMP TEMP is:
1. More than 152 F (66.7 C) or
2. The OIL SUMP TEMP is more than 142 F (61.1 C) and
also warmer than the CALC EVAP SAT TEMP plus
55 F (30.6 C).
36
Table 5 — Protective Safety Limits and Control Settings
ALARM OR
ALERT STATE
260-271, 140,141
-40 deg F>Temperature>245 deg F for 3 seconds
Pressure Transducers Out of Range
High Compressor Discharge
Temperature
262-272
231
162
103
0.06>Voltage Ratio>0.98 for 3 seconds
COMP DISCHARGE TEMP > 180 deg F(82 deg C)
COMP DISCHARGE TEMP > COMP DISCHARGE ALERT
COMP DISCHARGE TEMP > COMP DISCHARGE ALERT - 10 deg F(5.6 deg C)
High Motor Temperature
233
COMP MOTOR WINDING TEMP > 244 deg F(118 deg C) or < -5 deg F(-21 deg C)
— Open Circuit
COMP MOTOR WINDING TEMP > COMP MOTOR TEMP OVERRIDE - 10 deg F(5.6 deg C)
MONITORED PARAMETER
Temperature Sensors Out of Range
102
Low Evaporator Temperature (Freeze
Protection)
243
232
104
LIMIT
Chiller in RECYCLE SHUTDOWN and CALC EVAP SAT TEMP or EVAP REFRIG LIQUID
TEMP < EVAP REFRIG TRIPPOINT + 1 deg F
For water: EVAP REFRIG LIQUID TEMP or CALC EVAP SAT TEMP TEMP < 33 deg F and
EVAPORATOR APPROACH < EVAP APPROACH ALERT
For brine: EVAP REFRIG LIQUID TEMP or CALC EVAP SAT TEMP is between 0 deg F(-17.8C)
and 40 deg F(4.4C)(brine) and EVAPORATOR APPROACH < EVAP APPROACH ALERT
CALC EVAP SAT TEMP < 33 deg F + REFRIG OVERRIDE DELTA T (non-brine)
CALC EVAP SAT TEMP < EVAP REFRIG TRIPPOINT (brine) + REFRIG OVERRIDE DELTA T
Transducer Voltage Fault
High Condenser Pressure
- Control
- Switch
- Prestart
Low Condenser Pressure (Freeze
Protection)
239
TRANSDUCER VOLTAGE REF<4.5 VDC
235
207
106
CONDENSER PRESSURE > 166 PSI
High Pressure Switch Open(165 +/-5 PSIG) & VFD START = YES
CONDENSER PRESSURE > COND PRESS OVERRIDE - 25 PSI
244
Chiller in PUMPDOWN mode and CONDENSER REFRIG TEMP < CONDENSER FREEZE
POINT
Energizes condenser pump relay if CONDENSER REFRIG TEMP < CONDENSER FREEZE
POINT. De-energizes condenser pump relay when CONDENSER REFRIG TEMP
> CONDENSER FREEZE POINT + 5 deg F (2.8 deg C) and ENTERING COND LIQUID
> CONDENSER FREEZE POINT
154
Oil
- Low Pressure
- Low Pressure
- Low Pressure
- High Oil Pressure
- Pressure Sensor Fault
- Low Temperature
234
228
142
164
227
105
COMMENTS
Preset Alarm. See Temperature vs. Resistance/Voltage Drop
in Table 13A and 13B
Preset Alarm Voltage Ratio=Input Voltage/Voltage Reference(5 Volts)
Preset Alarm, Configure DISCH TEMP ALERT in SETUP1 screen
Configure COMP DISCH ALERT in SETUP1 screen
Prestart Alert, Configure COMP DISCHARGE ALERT in SETUP1
screen
Preset Alarm
Prestart Alert, Configure COMP MOTOR TEMP OVERRIDE in
SETUP1 screen
Preset Alarm, Configure EVAP REFRIG TRIPPOINT in SETUP1
screen
Preset Alarm, Configure EVAP APPROACH ALERT in SETUP1
screen
Configure EVAP APPROACH ALERT and CHILLED MEDIUM in
SETUP1 screen
Prestart Alert, Configure REFRIG OVERRIDE DELTA T in SETUP1
screen
Prestart Alert, Configure EVAP REFRIG TRIP POINT and CHILLED
MEDIUM in SETUP1 screen
Preset Alarm
Preset Alarm
Preset Alarm, Switch closes at 110 +/-7 PSIG
Prestart Alert, Configure COND PRESS OVERRIDE in SETUP1
screen
Preset Alarm, Configure CONDENSER FREEZE POINT in SETUP1
screen.
Configure CONDENSER FREEZE POINT in SETUP1 screen
OIL PRESSURE DELTA P < 18 PSID after OIL PUMP = ON, OIL PRESS VERIFY TIME
exceeded, and STARTUP in progress
OIL PRESSURE DELTA P < 15 PSID and VFD START = TRUE
OIL PRESSURE DELTA P < 15 PSID and VFDSTART = TRUE
Oil Pump ON and OIL PRESSURE DELTA P > 45 PSI
OIL PRESSURE DELTA P > 4 PSI immediately before oil pump turned on
OIL SUMP TEMP < 140 deg F and OIL SUMP TEMP < CALC EVAP SAT TEMP + 15 deg F
(8.3 deg C)
Preset Alarm, Configure OIL PRESS VERIFY TIME in SETUP1
screen
Preset Alarm, condition must persist for 55 consecutive seconds
Preset Alert, condition must persist for 10 consecutive seconds
Preset Alert, condition must persist for 55 consecutive seconds
Preset Alarm
Preset Prestart Alert
Line Voltage
- High
- High
- Low
- Low
- Imbalance
211/145
108
212/146
107
216
Line voltage > limits are calculated by VFD (alert is declared if AUTORESTART is ENABLED)
PERCENT LINE VOLTAGE > 115%
Line voltage < limits calculated by VFD (alert is declared if AUTORESTART is ENABLED)
PERCENT LINE VOLTAGE < 85%
LINE VOLTAGE IMBALANCE > LINE VOLTAGE % IMBALANCE
Preset Alarm/Autorestart Alert
Configure LINE VOLTAGE % IMBALANCE and LINE VOLT
IMBALANCE TIME in VFD_CONF screen
Line Current
- Dropout
- Imbalance
210/144
209/143
Line Voltage on 2 Phases < 50% for 1 Cycle
LINE CURRENT IMBALANCE>LINE CURRENT % IMBALANCE
Configure LINE CURRENT % IMBALANCE and LINE CURRENT
IMBALANCE TIME in VFD_CONF screen
Power
- Line Frequency Trip
- Power Loss
- Phase Reversal
Motor
- Stall
222
214/148
226
47 Hz < LINE FREQUENCY < 63 Hz
DC BUS VOLTAGE<85% for Excessive Time Period
Line power phases out of sequence
Preset Alarm
Preset Alarm
238
> 5 stall events within STALL TIME PERIOD
- Current Imbalance
225
MOTOR CURRENT IMBALANCE>MOTOR CURRENT % IMBALANCE
- Rotation Reversed
- Overload Trip
221
217
DISCHARGE PRESSURE decreases more than 2 PSI after VFDSTART = TRUE
Any LOAD CURRENT PHASE > 108% for Excessive Time Period
- Excessive Amps
- Acceleration Fault
208
203
PERCENT LOAD CURRENT > 110% for 30 sec.
PERCENT LOAD CURRENT > 95% at startup and VFDSTART = TRUE for 5 to 40 sec
- Amps not Sensed
202
PERCENT LOAD CURRENT < 5% and VFD START=TRUE for 20 sec
- Starts Limit Exceeded
Low Chilled Liquid Flow
100
229
Low Cond Liquid Flow
230
Preset Alarm, Configure STALL DELTA% AMPS and STALL TIME
PERIOD in OPTIONS screen
Configure MOTOR CURRENT % IMBALANCE and MOTOR CURRENT IMBAL TIME in VFD_CONF screen
Preset Alarm, Must be outside -2 PSI limit for 5 consecutive samples
Preset Alarm, Configure MOTOR LOAD ACTIVE DEMAND LIMIT in
MAINSTAT screen
Preset Alarm
Preset Alarm, PERCENT LOAD CURRENT = AVERAGE LOAD
CURRENT/MOTOR RATED LOAD AMPS
Configurable Alarm, Configure LIQUID FLOW VERIFY TIME in
SETUP1 screen.
EVAPORATOR APPROACH = LEAVING CHILLED LIQUID TEMP EVAP REFRIG LIQUID TEMP
Configurable Alarm, Configure LIQUID FLOW VERIFY TIME in
SETUP1 screen.
CONDENSER APPROACH = CONDENSER REFRIG TEMP LEAVING COND LIQUID TEMP
Configure EVAP APPROACH ALERT in SETUP1 screen
EVAPORATOR APPROACH = LEAVING CHILLED LIQUID TEMP EVAP REFRIG LIQUID TEMP
Configure COND APPROACH ALERT in SETUP1 screen.
High Approach-Evaporator
160
More than 8 starts in 12 hours
CHILLED LIQUID FLOW = FALSE after CHILLED LIQUID PUMP = ON & LIQUID FLOW VERIFY TIME elapsed. CHILLED LIQUID DELTA P < EVAP FLOW DELTA P CUTOUT or CALC
EVAP SAT TEMP < EVAP REFRIG TRIPPOINT or EVAPORATOR APPROACH > EVAP
APPROACH ALERT and EVAP REFRIG LIQUID TEMP < EVAP REFRIG TRIPPOINT +1
COND LIQUID FLOW = FALSE after COND LIQUID PUMP = ON & LIQUID FLOW VERIFY
TIME elapsed. CONDENSER LIQUID DELTA P < COND FLOW DELTA P CUTOUT or CONDENSER APPROACH > CONDENSER APPROACH ALERT, or CONDENSER PRESSURE >
COND PRESS OVERRIDE + 5
EVAPORATOR APPROACH > EVAP APPROACH ALERT and VFD START = TRUE
- Condenser
161
CONDENSER APPROACH > COND APPROACH ALERT and VFD START = TRUE
245
204
ACTUAL VFD SPEED < VFD SPEED OUTPUT - 10% or ACTUAL VFD SPEED > VFD SPEED
OUTPUT + 10%
PERCENT LOAD CURRENT >15% and VFDSTART = NO for 20 sec
VFD
- Speed Out of Range
- Failure to Stop
- Communication Failure
Rectifier
- Overcurrent
- High Temperature
Inverter
- Overcurrent
- High Temperature
High VFD Inductor Temperature
DC Bus Voltage
- High
- Low
Ground Fault
Optional Limits
- Spare Temperature
Preset Alarm, Must be outside +/-10% range for 75 sec.
Preset Alarm
224
Communication with VFD lost for more than 10 sec
241
218
101
RECTIFIER OVERCURRENT exceeded limit determined by VFD
RECTIFIER TEMPERATURE >exceeds limit calculated by VFD
RECTIFIER TEMPERATURE > RECTIFIER TEMP OVERRIDE - 20 deg F(11.1 deg C)
Preset Alarm
Preset Alarm
Prestart Alert, Configure RECTIFIER TEMP OVERRIDE in SETUP1
screen
246
219
109
INVERTER OVERCURRENT exceeded limit determined by VFD
INVERTER TEMPERATURE >exceeds limit calculated by VFD
INVERTER TEMPERATURE > INVERTER TEMP OVERRIDE - 20 deg F(11.1 deg C)
255
Inductor Temperature Switch Open
Preset Alarm
Preset Alarm
Prestart Alert, Configure INVERTER TEMP OVERRIDE in SETUP1
screen
Preset Alarm
205/150
215/149
220
DC BUS VOLTAGE Limit Exceeded, limit is calculated by VFD
DC BUS VOLTAGE < approximately 407VDC @400/480V Line Side Voltage
GROUND FAULT CURRENT > 7% of Drive Rated Amps Sensed
Preset Alarm
Optional Alarm, Configure SPARE TEMP ENABLE and SPARE
TEMP LIMIT in SETUP1 screen
Optional Alert, Configure SPARE TEMP ENABLE and SPARE TEMP
LIMIT in SETUP1 screen
Optional Alarm, configure PPM AT 20 MA and REFRIGERANT LEAK
ALARM PPM in OPTIONS screen.
248,249
SPARE TEMPERATURE > SPARE TEMP LIMIT for 3 consecutive samples
- Spare Temperature
158,159
SPARE TEMPERATURE > SPARE TEMP LIMIT for 3 consecutive samples
- Refrigerant Leak Sensor
250
REFRIGERANT LEAK SENSOR PPM > REFRIG LEAK ALARM PPM
37
followed by the LOCAL or CCN softkey. This ensures that,
if the automatic system is malfunctioning, the chiller will not
repeatedly cycle on and off. If the AUTORESTART OPTION
and the REMOTE CONTACT OPTION in the OPTIONS
screen are enabled, the REMOTE CONTACTS must be closed
in order for the chiller to restart following a power failure. If
the automatic restart after a power failure option (AUTO
RESTART OPTION on the OPTIONS screen) is not enabled
when a power failure occurs, and if the remote contact is
closed, the chiller will indicate an alarm because of the loss of
voltage.
Oil Sump Temperature Control COMPRESSOR ON — The oil heater relay is energized whenever the
chiller compressor is on, and the OIL SUMP TEMP is less than
90 F (32.2 C) or OIL SUMP TEMP is less than the CALC
EVAP SAT TEMP plus 35 F (19.4 C). The oil heater is then
turned off when the OIL SUMP TEMP is:
1. More than 90 F (32.2 C).
2. The OIL SUMP TEMP is warmer than the CALC
EVAP SAT TEMP plus 35 F (19.4 C).
All oil filter isolation valves should always be left open,
except when changing the oil or the oil filter as defined in
Changing Oil and Oil Filter section, page 73.
The contacts for remote start are wired into terminals 23 and
24 of the low voltage terminal strip in the control center
cabinet. See the certified drawings for further details on contact
ratings. The contacts must have 24 vac rating.
Remote Start/Stop Contacts — A remote device,
Spare Safety and Spare Temperature Inputs —
Normally closed (NC) discrete inputs for additional fieldsupplied safeties may be wired to the spare protective limits
input channel in place of the factory-installed jumper. (Wire
multiple inputs in series.) The opening of any contact will
result in a safety shutdown and a display on the ICVC. Refer to
the certified drawings for safety contact ratings.
Analog temperature sensors may also be added to the module (SPARE TEMPERATURE #1 and #2). The analog temperature sensors may be configured to cause an alert or alarm on
the CCN network. The alert will not shut the chiller down.
Configuring for alarm state will cause the chiller to shut down.
The SPARE TEMP channels can be configured for low or high
temperature limits in the SETUP1 screen.
such as a timeclock that uses a set of contacts, may be used to
start and stop the chiller. However, the device should not be
programmed to start and stop the chiller in excess of 2 or
3 times every 12 hours. If more than 8 starts in 12 hours (the
STARTS IN 12 HOURS parameter on the MAINSTAT screen)
occur, an excessive starts prestart alert displays, preventing the
chiller from starting. The operator must press the RESET
softkey on the ICVC to override the starts counter and start the
chiller. If the chiller records 12 starts (excluding recycle starts
or auto restarts after power failure) in a sliding 12-hour period,
it can be restarted only by pressing the RESET softkey
Table 6 — Capacity Overrides
OVERRIDE
CAPACITY CONTROL
High Condenser Pressure
(COND PRESS OVERRIDE)
FIRST STAGE SET POINT
View/Modify
on ICVC Screen
SETUP1
Default
Value
Configurable
Range
SECOND STAGE
SET POINT
SECOND STAGE
OVERRIDE
TERMINATION
Value
Value
CONDENSER PRESSURE >
COND PRESS OVERRIDE
145 PSIG 145 to 166 PSIG
+ 2.4 PSIG(16.5 kPa) OR
(1000 kPa) (1000 to 1145 kPa) CONDENSER PRESSURE
> 163 PSIG (1124 kPa)
CONDENSER
PRESSURE
< CONDENSER
PRESS
OVERRIDE
- 1 PSI (6.9 kPa)
SETUP1
3° F
(1.7° C)
2 to 5° F
(1.1 to 2.8° C)
CALC EVAP SAT TEMP, or
EVAP REFRIG LIQUID
TEMP < EVAP SAT
OVERRIDE TEMP
- 1° F (.6° C) NOTE: EVAP
SAT OVERRIDE TEMP =
EVAP REFRIG TRIPPOINT +
REFRIG OVERRIDE DELTA T
High Motor Temperature
SETUP1
(COMP MOTOR TEMP OVERRIDE)
200° F
(93° C)
150 to 200° F
(66 to 93° C)
COMP MOTOR WINDING
TEMP > COMP MOTOR TEMP
OVERRIDE + 10° F (5.6° C)
COMP MOTOR
WINDING TEMP <
COMP MOTOR
TEMP OVERRIDE
- 2° F (1.1° C)
Low Evaporator Temperature
(REFRIG OVERRIDE DELTA T)
CALC EVAP SAT
TEMP and
EVAP REFRIG
LIQUID TEMP >
EVAP SAT
OVERRIDE
TEMP + 2° F (1.1° C)
High Rectifier Temperature
(RECTIFIER TEMP OVERRIDE)
SETUP1
160° F
(71° C)
155 to 170° F
(68 to 77° C)
RECTIFIER TEMP >
RECTIFIER TEMP
RECTIFIER
TEMP < RECTIFIER
TEMP OVERRIDE
- 5° F (2.8° C)
High Inverter Temperature
(INVERTER TEMP OVERRIDE)
SETUP1
160° F
(71° C)
155 to 170° F
(68 to 77° C)
INVERTER TEMP >
INVERTER TEMP
INVERTER TEMP <
INVERTER TEMP
OVERRIDE
- 5° F (2.8° C)
38
Spare Alarm Contacts — One normally open trip
alarm contact is provided in the control center cabinet. The
contact ratings are provided in the certified drawings. The
contacts are located on terminals 9 and 10 of the hazardous
voltage terminal strip in the control center cabinet.
If the CONDENSER PRESSURE is greater than or equal to
the COND PRESS OVERRIDE, the condenser pump will energize to try to decrease the pressure and Alert 151 will be generated. The pump will turn off when the condenser pressure is
less than the COND PRESS OVERRIDE threshold.
Refrigerant Leak Detector — A 4 to 20 mA / 0 to
Condenser Freeze Prevention — This control algo-
rithm helps prevent condenser tube freeze-up by energizing the
condenser pump relay through terminals 3 and 4 of the hazardous voltage terminal strip (TB2) in the Control Center. The
PIC III controls the pump and, by starting it, helps to prevent
the liquid in the condenser from freezing. The PIC III can
perform this function whenever the chiller is not running except when it is either actively in pumpdown or in pumpdown/
lockout with the freeze prevention disabled.
When the CONDENSER REFRIG TEMP is less than or
equal to the CONDENSER FREEZE POINT, the CONDENSER LIQUID PUMP is energized until the CONDENSER
REFRIG TEMP is greater than the CONDENSER FREEZE
POINT plus 5º F (2.7º C) and the ENTERING CONDENSER
LIQUID TEMPERATURE is greater than or equal to the
CONDENSER FREEZE POINT. An alarm (244) is generated
if the chiller is in PUMPDOWN mode and the pump is energized. An alert (154) is generated if the chiller is not in PUMPDOWN mode and the pump is energized. If the chiller is in
RECYCLE SHUTDOWN mode, the mode will transition to a
non-recycle shutdown.
5 vdc input is available on the CCM module [terminal J5-5 (–)
and J5-6 (+)] for a refrigerant leak detector. Enabling REFRIGERANT LEAK OPTION (OPTIONS screen) will allow the PIC
III controls to go into an alarm state at a user configured level
(REFRIG LEAK ALARM mA). The input is configured for 4 to
20 mA by setting CCM DIP switch 1 on SW2 at the ON position, or configured for 1 to 5 vdc by setting switch 1 at the OFF
position. The output of the refrigerant leak detector is displayed
as REFRIG LEAK SENSOR PPM on the MAINSTAT screen.
For a 1 to 5 vdc input, 1 vdc input represents 4 mA displayed
and 5 vdc input represents 20 mA displayed.
4 to 20 mA Kilowatt Output — An output is available on the CCM module [Terminal J8-1 (+) and J8-2 (–)] to
represent the power consumption of the chiller. The 4 to 20 mA
signal generated by the CCM module can be wired to the building automation or energy management system to monitor the
chiller’s energy consumption. A 4 mA signal represents the
chiller in an off state and a 20 mA signal represents the chiller
operating at its rated peak kilowatt consumption. The rated
peak kilowatt consumption is configured by the user in the
VFD_CONF display screen by the setting the RATED LINE
KILOWATTS from the Machine Electrical Data Nameplate.
The kilowatt output is designed for use with non-grounded
controllers with a maximum input impedance of 500 ohms.
Tower Fan Relay Low and High — Low condenser
liquid temperature can cause the chiller to shut down if it causes the condenser refrigerant temperature to be too low. The
tower fan relays, located on terminals 5-8 on the hazardous
voltage terminal strip (TB2) in the Control Center, are controlled by the PIC III to energize and deenergize as the pressure
differential between cooler and condenser vessels changes.
This prevents excessively low condenser liquid temperatures.
The tower fan relay can only accomplish this if the relay has
been added to the cooling tower temperature controller.
The tower fan relay low is turned on whenever the condenser liquid pump is running, flow is verified, the difference
between cooler and condenser pressure is more than 30 psid
(207 kPad), and the ENTERING CONDENSER LIQUID
temperature is greater than 65 F (18.3 C).
The tower fan relay low is turned off when the CONDENSER LIQUID PUMP is deenergized, when CONDENSER
LIQUID FLOW indication is lost, or under the following
conditions:
1. CALC EVAP SAT TEMP is less than EVAP SAT
OVERRIDE TEMP.
2. The difference between the CONDENSER PRESSURE
and EVAPORATOR PRESSURE is less than 25 psi
(172 kPa).
The tower fan relay high is turned on whenever the
condenser liquid pump is running, flow is verified and the
difference between cooler and condenser pressure is more than
35 psid (241.3 kPa) for ENTERING COND LIQUID temperature greater than the TOWER FAN HIGH SETPOINT
(SETPOINT menu, default 75 F [24 C]).
The tower fan relay high is turned off when the condenser
pump is off, flow is stopped, or the CALC EVAP SAT TEMP is
less than the EVAP SAT OVERRIDE TEMP and ENTERING
CONDENSER LIQUID is less than 70 F (21.1 C), The tower
fan relay high is also turned off when the difference between
CONDENSER PRESSURE and EVAPORATOR PRESSURE is
less than 28 Psid (193 kPa), and ENTERING CONDENSER
LIQUID temperature is less than TOWER FAN HIGH SETPOINT minus 3 F (1.6 C).
Remote Reset of Alarms — A standard feature of the
PIC III controls is the ability to reset certain faults on a chiller
in a shutdown alarm state from a remote location. If the condition which caused the alarm has cleared the fault can be reset
and the chiller can be placed back into a normal CCN operating
mode when the REMOTE RESET OPTION (ICVC_PWD
menu) is set to ENABLE. A variety of Carrier Comfort Network® software systems including ComfortVIEW™ or Network Service Tool® can access the PIC III controls and reset
certain displayed alarms. Third party software from building
automation systems (BAS) or energy management systems
(EMS) can also access the PIC III controls through a Carrier
DataLINK™, Dataport™, or LEI (Local Equipment Interface)
module and reset certain faults displayed. All methods would
access the ICVC_PWD screen and force the RESET ALARM?
point to YES to reset the fault condition. If the PIC III controls
have determined that it is safe to start the chiller the CCN
MODE? point (ICVC_PWD screen) can be forced to YES to
place the chiller back into normal CCN operating mode. The
only exceptions are the following alarms that cannot be reset
from a remote location: ALARM STATES #200, 201, 204,
206, 217, 218, 219, 220 and 236. To view alarm codes, refer to
Troubleshooting Guide, Checking Display Messages, page 79.
After the alarm has been reset the PIC II control will increment
the Starts in 12 Hours counter by one upon restart. If the limit
of 8 starts in a 12-hour period occurs Prestart Alert 100 must be
manually reset at the local chiller control panel (ICVC).
Condenser Pump Control — The chiller will moni-
tor the condenser pressure (CONDENSER PRESSURE) and
may turn on the condenser pump if the condenser pressure
becomes too high while the compressor is shut down. The
condenser pressure override (COND PRESS OVERRIDE)
parameter is used to determine this pressure point. COND
PRESS OVERRIDE is found in the SETUP1 display screen,
which is accessed from the EQUIPMENT SERVICE table.
The default value is 145 psig (543 kPa).
39
2 permits ±30 F (±17 C) of automatic reset to the ECL
SETPOINT or LCL SETPOINT based on a temperature sensor
wired to the CCM module (see wiring diagrams or certified
drawings). The temperature sensor must be wired to CCM
terminal J4-13 and J4-14.
To configure Reset Type 2, enter the temperature of the
remote sensor at the point where no temperature reset will
occur (REMOTE TEMP -> NO RESET). Next, enter the
temperature at which the full amount of reset will occur
(REMOTE TEMP -> FULL RESET). Then, enter the maximum amount of reset required to operate the chiller
(DEGREES RESET). Reset Type 2 can now be enabled.
RESET TYPE 3 — Reset Type 3 is an automatic chilled liquid
temperature reset based on the difference between ENTERING CHILLED LIQUID and LEAVING CHILLED LIQUID
temperature. Reset Type 3 adds ±30 F (±17 C) based on the
chilled liquid temperature difference.
To configure Reset Type 3, enter the chilled liquid temperature difference (the difference between entering and leaving
chilled liquid) at which no temperature reset occurs (CHL
DELTA T -> NO RESET). This chilled liquid temperature
difference is usually the full design load temperature
difference. Next, enter the difference in chilled liquid temperature at which the full amount of reset occurs (CHL DELTA T ->
FULL RESET). Finally, enter the amount of temperature reset
(DEGREES RESET). Reset Type 3 can now be enabled.
Demand Limit Control Option — The demand limit
control option (20 mA DEMAND LIMIT OPT) is externally
controlled by a 4 to 20 mA or 1 to 5 vdc signal from an energy
management system (EMS). The option is set up on the
RAMP_DEM screen. When enabled, 4 mA is the 100%
demand set point with an operator-configured minimum
demand at a 20 mA set point (DEMAND LIMIT AT 20 mA).
The auto. demand limit is hardwired to terminals J5-1 (–)
and J5-2 (+) on the CCM. Switch setting number 1 on CCM
SW2 will determine the type of input signal. With the switch
set at the ON position the input is configured for an externally
powered 4 to 20 mA signal. With the switch in the OFF position the input is configured for an external 1 to 5 vdc signal.
One of the following modifications are also required when using a 1 to 5 vdc DEMAND LIMIT signal:
1. Install a 25 ohm resistor in series with the (+) voltage
lead connected to CCM terminal J5-2.
2. Modify the input voltage signal with an external controller software to calibrate the temperature interpreted
by the CCM. The controller should provide 4.54 v at
100% of the controller’s output range and 0.91 v at 0%
of the controller’s output range.
The TOWER FAN RELAY LOW and HIGH parameters
are accessed from the STARTUP screen.
IMPORTANT: A field-supplied liquid temperature control
system for condenser liquid should be installed. The system should maintain the leaving condenser liquid temperature at a temperature that is 20º F (11º C) above the leaving
chilled liquid temperature.
The tower fan relay control is not a substitute for a condenser liquid temperature control. When used with a liquid
temperature control system, the tower fan relay control can
be used to help prevent low condenser liquid temperatures.
Auto. Restart After Power Failure — This option
may be enabled or disabled and may be viewed or modified on
the OPTIONS screen, which is accessed from the SERVICE
table. If the AUTO. RESTART option is enabled, the chiller
will start up automatically after a power failure has occurred
(after a single cycle dropout; low, high, or loss of voltage; and
the power is within ±10% of normal). The 15 and 3-minute
inhibit timers are ignored during this type of start-up.
When power is restored after the power failure, a power
failure restart will be enabled and the control allowed to
AUTORESTART the chiller, starting with the chilled liquid
pump(s), if start-up conditions are met.
If power to the ICVC module has been off for more than
3 hours or the timeclock has been set for the first time, the
compressor will start with the slowest temperature-based ramp
load rate possible in order to minimize oil foaming.
Liquid/Brine Temperature Reset — Three types of
chilled liquid or brine setpoint temperature reset are available
and can be viewed or modified on the TEMP_CTL screen,
which is accessed from the EQUIPMENT SERVICE table.
The ICVC default screen indicates when the chilled liquid
reset is active. TEMPERATURE RESET on the MAINSTAT
screen indicates the amount of reset. The CONTROL POINT
will be determined by adding the TEMPERATURE RESET to
the ECL SETPOINT or LCL SETPOINT.
To activate a reset type, access the TEMP_CTL screen and
input all configuration information for that reset type. Then,
input the reset type number (1, 2, or 3) in the SELECT/
ENABLE RESET TYPE input line.
RESET TYPE 1: 4 to 20 mA (0 to 5 vdc) TEMPERATURE
RESET — Reset Type 1 is an automatic chilled liquid temperature reset based on a remote temperature sensor input configured for either an externally powered 4 to 20 mA or a 0 to
5 vdc signal. Reset Type 1 permits up to ±30 F (±17 C) of
automatic reset to the ECL SETPOINT or LCL SETPOINT.
The auto, chilled liquid reset is hardwired to CCM terminals
J5-3 (–) and J5-4 (+). Switch setting number 2 on SW2 will
determine the type of input signal. With the switch set at the
ON position the input is configured for an externally powered
4 to 20 mA signal. With the switch in the OFF position the
input is configured for an external 0 to 5 vdc signal. One of the
following modifications are also required when using a 1 to
5 vdc temperature reset signal:
1. Install a 25 ohm resistor in series with the (+) voltage
lead connected to CCM terminal J5-4.
2. Modify the input voltage signal with an external controller software to calibrate the temperature interpreted
by the CCM. The controller should provide 4.54 v at
100% of the controller’s output range and 0.91 v at 0%
of the controller’s output range.
RESET TYPE 2: REMOTE TEMPERATURE RESET —
Reset Type 2 is an automatic chilled liquid temperature reset
based on a remote temperature sensor input signal. Reset Type
Hot Gas Bypass (Optional) Algorithm (See
Fig. 22A, 22B, and 23) — If a hot gas bypass solenoid
valve is present and the HGBP OPTION in the OPTIONS table
is set to 1 or 2, this operator configurable feature can determine
if load conditions are too low for the compressor and corrective
action can be taken.
When the HGBP OPTION = 0: the HGBP algorithm is
disabled.
When the HGBP OPTION = 1, the algorithm determines if
corrective action is necessary by checking the chiller operating
point against an operator configured threshold. The threshold is
calculated from a combination of the difference between Entering and Leaving Chilled Liquid temperatures and the difference between CONDENSER PRESSURE and EVAPORATOR PRESSURE. The operator configured data points are the
MIN LOAD POINT(T1/P1) and the FULL LOAD POINT
(T2/P2). These points have default settings defined in the
OPTIONS screen and on Table 3. A line is drawn between
these points as shown in Fig. 22A and 22B. The default Load
Points (to prevent compressor stall) are shown. Whenever the
40
ACTIVE DELTA T (actual temperature difference between the
LEAVING CHILLED LIQUID and ENTERING CHILLED
LIQUID) is on the left side of the line plotted in Fig. 22A and
22B, the algorithm will energize the hot gas bypass valve to
falsely load the chiller. If the ACTIVE DELTA T falls to the
right side of the line plotted in Fig 22A and 22B by more than
the HGBP DEADBAND, the hot gas bypass valve is deenergized. The HGBP valve is also deenergized if the ACTIVE
DELTA P (actual difference between CONDENSER PRESSURE and EVAPORATOR PRESSURE) falls to below HGBP
DELTA P1. Instructions to configure the MIN LOAD
POINT(T1/P1) and FULL LOAD POINT(T2/P2) are on
page 60.
When the HGBP OPTION = 2, the option energizes the Hot
Gas Bypass relay solely based on the ACTIVE DELTA T
(actual temperature difference between the LEAVING
CHILLED LIQUID and ENTERING CHILLED LIQUID).
Evaluation of the ACTIVE DELTA T begins at the completion
of ramp loading. The hot gas bypass valve is energized if the
ACTIVE DELTA T is less than the HGBP ON DELTA T. The
hot gas bypass relay will be turned off when the ACTIVE
DELTA T is greater than or equal to the sum of HGBP ON
DELTA T plus HGBP OFF DELTA T. See Fig. 23.
a23-1609
DEFAULT VALUES:
LEGEND
ΔP
—
ΔT
ECL
LCL
HGBP
Condenser PressureCooler Pressure
— ECL-LCL
— Entering Chilled
Liquid Temperature
— Leaving Chilled
Liquid Temperature
— Hot Gas Bypass
POINT
ΔT1
ΔP1
ΔT2
ΔP2
HFC-134a
0.8
1034
2.2
1379
Fig. 22B — 23XRV Hot Gas Bypass Option 1 (SI)
Head Pressure Output Reference (See
Fig. 24) — The PIC III control outputs a 4 to 20 mA signal
HGBP OFF
DELTA T
for the configurable Delta P (CONDENSER PRESSURE –
EVAPORATOR PRESSURE) reference curve shown in
Fig. 24. The DELTA P AT 100% (default at 50 psi). DELTA P
AT 0% (default at 25 psi) and MINIMUM OUTPUT are
configurable in the EQUIPMENT SERVICE-OPTIONS table.
When configuring this output, ensure that minimum requirements for proper condenser FLASC orifice performance
are maintained. The 4 to 20 mA output from VFD TB1
terminals 17 and 18 can be used as a reference to control a
tower bypass valve, tower speed control, or condenser pump
speed control. The head pressure output is designed for use
with non-grounded controllers with a maximum input
impedence of 500 ohms.
NOTE: It is up to the site design engineering agent to integrate
this analog output with any external system device(s) to produce the desired effect. Carrier does not make any claim that
this output is directly usable to control any specific piece of
HGBP Off As ACTIVE
DELTA T Decreases
ΔP
HGBP
Off
HGBP
On
HGBP On As ACTIVE
DELTA T Increases
HGBP ON
DELTA T
ΔT
a23-1636
LEGEND
ΔP
ΔT
HGBP
— Condenser Pressure –
Evaporator Pressure
Entering Chilled Liquid –
— Hot Gas Bypass
—
Fig. 23 — Hot Gas Bypass Option 2
DELTA P
AT 100%
DELTA P
NON-ZERO
EXAMPLE
OF
MINIMUM HEAD
PRESSURE REFERENCE
OUTPUT
a23-1608
LEGEND
ΔP
—
ΔT
ECL
—
—
LCL
—
HGBP
—
Condenser PressureCooler Pressure
ECL-LCL
Entering Chilled
Liquid Temperature
Leaving Chilled
Liquid Temperature
Hot Gas Bypass
DELTA P
AT 0%
DEFAULT VALUES:
POINT
ΔT1
ΔP1
ΔT2
ΔP2
HFC-134a
1.5
150
4
200
0 mA 2 mA 4 mA
(0%)
a23-1610
Fig. 22A — 23XRV Hot Gas Bypass
Option 1 (English)
4 T0 20 mA OUTPUT
Fig. 24 — Head Pressure Output
Reference Control
41
20 mA
(100%)
If return chilled liquid control is required on chillers piped
in series, the common point return chilled liquid sensor should
be installed. If this sensor is not installed, the return chilled
liquid sensor of the downstream chiller must be relocated to the
return chilled liquid pipe of the upstream chiller.
To properly control the common supply point temperature
sensor when chillers are piped in parallel, the liquid flow path
through the shutdown chillers must be isolated so no liquid
bypass around the operating chiller occurs. The common point
sensor option must not be used if liquid bypass around the
operating chiller is occurring.
CHILLER COMMUNICATION WIRING — Refer to the
chiller’s Installation Instructions, Carrier Comfort Network®
Interface section for information on chiller communication
wiring.
LEAD/LAG OPERATION — The PIC III not only has the
ability to operate 2 chillers in lead/lag, but it can also start a
designated standby chiller when either the lead or lag chiller is
faulted and capacity requirements are not met. The lead/lag
option only operates when the chillers are in CCN mode. If any
other chiller configured for lead/lag is set to the LOCAL or
OFF modes, it will be unavailable for lead/lag operation.
Lead/Lag Chiller Configuration and Operation
• A chiller is designated the lead chiller when its LEAD/
LAG CONFIGURATION value on the LEADLAG
screen is set to “1.”
• A chiller is designated the lag chiller when its LEAD/
LAG CONFIGURATION value is set to “2.”
• A chiller is designated as a standby chiller when its
LEAD/LAG CONFIGURATION value is set to “3.”
• A value of “0” disables the lead/lag designation of a
chiller.
To configure the LAG ADDRESS value on the LEADLAG
screen, always enter the address of the other chiller on the
system. For example, to configure chiller A, enter the address
for chiller B as the lag address. To configure chiller B, enter the
address for chiller A as the lag address. This makes it easier to
rotate the lead and lag chillers.
If the address assignments in the LAG ADDRESS and
STANDBY ADDRESS parameters conflict, the lead/lag function is disabled and an alert (!) message displays. For example,
if the LAG ADDRESS matches the lead chiller’s address, the
lead/lag will be disabled and an alert (!) message displayed.
The lead/lag maintenance screen (LL_MAINT) displays the
message ‘INVALID CONFIG’ in the LEAD/LAG: CONFIGURATION and CURRENT MODE fields. Refer to Table 7.
equipment (that is, without further control elements or signal
conditioning), although it may be.
The head pressure reference output will be on whenever the
condenser pump is operating. It may also be manually operated
in CONTROLS TEST. When the head pressure differential is
less than the value entered for DELTA P AT 0%, the output will
be maintained at 4 mA. The output is 2 mA when the chiller is
not running.
Lead/Lag Control — The lead/lag control system auto-
matically starts and stops a lag or second chiller in a 2-chiller
liquid system. A third chiller can be added to the lead/lag
system as a standby chiller to start up in case the lead or lag
chiller in the system has shut down during an alarm condition
and additional cooling is required. Refer to Fig. 18 and 19 for
menu, table, and screen selection information. The output is
2 mA when the chiller is not running.
NOTE: The lead/lag function can be configured on the
LEADLAG screen, which is accessed from the SERVICE
menu and EQUIPMENT SERVICE table. See Table 3,
Example 21. Lead/lag status during chiller operation can be
viewed on the LL_MAINT display screen, which is accessed
from the SERVICE menu and CONTROL ALGORITHM
STATUS table. See Table 3, Example 12.
Lead/Lag System Requirements:
• all chillers in the system must have software capable of
performing the lead/lag function
• liquid pumps MUST be energized from the PIC III
controls
• liquid flows should be constant
• the CCN time schedules for all chillers must be identical
Operation Features:
• 2 chiller lead/lag
• addition of a third chiller for backup
• manual rotation of lead chiller
• load balancing if configured
• staggered restart of the chillers after a power failure
• chillers may be piped in parallel or in series chilled
liquid flow
COMMON POINT SENSOR INSTALLATION — In all
cases lead/lag operation does not require a common point
chilled liquid sensor. Common point sensors (Spare Temp #1
and #2) can be added to the CCM module, if desired. Spare
Temp #1 and #2 are wired to plug J4 terminals 25-26 and 27-28
(J4 lower, respectively). See the Lead/Lag Control Wiring on
page 116.
NOTE: If the common point sensor option is chosen on a
chilled liquid system, each chiller should have its own common point sensor installed. Each chiller uses its own common
point sensor for control when that chiller is designated as the
lead chiller. The PIC III cannot read the value of common
point sensors installed on the other chillers in the chilled liquid
system.
If leaving chilled liquid control (ECL CONTROL OPTION
is set to 0 [DSABLE], TEMP_CTL screen) and a common
point sensor is desired (COMMON SENSOR OPTION in
LEADLAG screen selected as 1) then the common point
temperature sensor is wired in Spare Temp #1 position on the
CCM.
If the entering chilled liquid control option (ECL CONTROL OPTION) is enabled (configured in TEMP_CTL
screen) and a common point sensor is desired (COMMON
SENSOR OPTION in LEADLAG screen selected as 1) then
the sensor is wired in Spare Temp #2 position on the CCM.
When installing chillers in series, a common point sensor
should be used. If a common point sensor is not used, the
leaving chilled liquid sensor of the upstream chiller must be
moved into the leaving chilled liquid pipe of the downstream
chiller.
Table 7 — Invalid Lead/Lag Addresses
LEAD/LAG
CONFIGURATION
(In LEAD/LAG Screen)
INVALID CONDITIONS
Local Address (Lead) =
Lag Address
1 (Lead)
Standby Chiller Option = Enable and
Local Address (Lead) = Standby Address
Lag Address = Standby Address
Local Address (Lead) =
Lag Address
2 (Lag)
Local Address (Lag) = Standby Address
The lead chiller responds to normal start/stop controls such
as the occupancy schedule, a forced start or stop, and remote
start contact inputs. After completing start-up and ramp loading, the PIC III evaluates the need for additional capacity. If
additional capacity is needed, the PIC III initiates the start-up
of the chiller configured at the LAG ADDRESS. If the lag
chiller is faulted (in alarm) or is in the OFF or LOCAL modes,
42
When all the above requirements have been met, the lag
chiller is commanded to a STARTUP mode (SUPVSR flashing
next to the point value on the STATUS table). The PIC III
control then monitors the lag chiller for a successful start. If the
lag chiller fails to start, the standby chiller, if configured is
started.
Lead/Lag Pulldown Timer Operation — Some lead/lag chiller applications with large chilled liquid loop volumes must
accommodate intermittent slugs of warm ENTERING
CHILLED LIQUID for short time periods. This type of transient condition can result when a control valve rapidly opens to
allow flow through a previously isolated branch or zone within
the chilled liquid system. A PULLDOWN TIMER can be configured to delay starting the lag chiller so it does not excessively cycle on and off for short time periods when intermittent
slugs of warm ENTERING CHILLED LIQUID pass through
the chillers. A larger PULLDOWN TIMER entry gives the
warm slug of water more time to pass through the chillers
before the lag chiller will start.
The chiller CONTROL POINT can be configured to either
LEAVING CHILLED LIQUID or ENTERING CHILLED
LIQUID temperature. The PIC Controls monitor the temperature pulldown rate of the CHILLED LIQUID and display the
result as CHILL LIQ PULLDOWN/MIN in the HEAT_EX
screen. Samples of the CHILLED LIQUID temperature are
taken once every 10 seconds and compared against the previous CHILLED LIQUID sample. A positive value of CHILL
LIQ PULLDOWN/MIN indicates that the CHILLED LIQUID
temperature is decreasing between successive samples. If
CHILL LIQ PULLDOWN/MIN rate is a minimum of
0.5 degrees F per minute then the PULLDOWN: SATISFIED
parameter in the LL_MAINT screen displays “YES”, otherwise, the PULLDOWN: SATISFIED parameter displays
“NO”.
If the lead chiller is unable to achieve the CONTROL
POINT, the lag chiller will not start unless the lead chiller is unable to maintain a CHILL LIQ PULLDOWN/MIN rate of
0.5 degrees F per minute for a time period equal to the number
of minutes entered in the PULLDOWN TIMER parameter.
PULLDOWN TIME in the LL_MAINT screen displays the
remaining delay left before the lag chiller is allowed to start
based on the pulldown timer. PULLDOWN TIME will count
down starting at the value entered in PULLDOWN TIMER
when Ramp Loading is complete and when PULLDOWN:
SATISIFIED = NO.
The lag chiller pulldown start condition is met when PULLDOWN TIME lapses to 0.0 min.
If PULLDOWN: SATISFIED changes to “YES” as the
PULLDOWN TIME is counting down to zero, the PULLDOWN TIME will start to count back up provided that the
CHILLED LIQUID temperature has not fallen to less than the
CONTROL POINT plus one half of the CHILLED LIQUID
DEADBAND. The PULLDOWN TIME will start to count back
down again should PULLDOWN: SATISFIED change back to
“NO”. The PULLDOWN TIME will be immediately reset to
the value entered in the PULLDOWN TIMER parameter if the
CHILLED LIQUID temperature decreases to less than the
CONTROL POINT plus one half of the CHILLED LIQUID
DEADBAND.
Lag Chiller Shutdown Requirements — The following conditions must be met in order for the lag chiller to be stopped.
1. Lead chiller AVERAGE LINE CURRENT or PERCENT
MOTOR KILOWATTS load value (on the MAINSTAT
screen) is less than the Lead Chiller Percent Capacity.
NOTE: Lead Chiller Percent Capacity = 105 – LAG %
CAPACITY. The LAG % CAPACITY parameter is on
the LEADLAG screen, which is accessed from the
EQUIPMENT SERVICE table on the SERVICE
menu.
the chiller at the STANDBY ADDRESS (if configured) is
requested to start. After the second chiller is started and is
running, the lead chiller monitors conditions and evaluates
whether the capacity has been reduced enough for the lead
chiller to sustain the system alone. If the capacity is reduced
enough for the lead chiller to sustain the CONTROL POINT
temperature alone, then the operating lag chiller is stopped.
If the lead chiller is stopped in CCN mode for any reason
other than an alarm (*) condition, the lag and standby chillers
are also stopped. If the configured lead chiller stops for an
alarm condition, the configured lag chiller takes the lead
chiller’s place as the lead chiller, and the standby chiller serves
as the lag chiller.
If the configured lead chiller does not complete the start-up
before the PRESTART FAULT TIMER (configured in LEADLAG screen) elapses, then the lag chiller starts and the lead
chiller shuts down. The lead chiller then monitors the start
request from the acting lead chiller. The PRESTART FAULT
TIMER is initiated at the time of a start request. The
PRESTART FAULT TIMER provides a timeout if there is a
prestart alert condition that prevents the acting lead chiller from
starting in a timely manner. The PRESTART FAULT TIMER
parameter is on the LEAD-LAG screen, which is accessed
from the EQUIPMENT SERVICE table of the SERVICE
menu.
If the lag chiller does not achieve start-up before the
PRESTART FAULT TIMER elapses, the lag chiller stops, and
the standby chiller is requested to start, if configured and ready.
Standby Chiller Configuration and Operation — A chiller is
designated as a standby chiller when its LEAD/LAG CONFIGURATION value on the LEADLAG screen is set to “3.” The
standby chiller can operate as a replacement for the lag chiller
only if one of the other two chillers is in an alarm (*) condition
(as shown on the ICVC panel). If both lead and lag chillers are
in an alarm (*) condition, the standby chiller defaults to operate
in CCN mode, based on its configured occupancy schedule and
remote contacts input.
Lag Chiller Start-Up Requirements — Before the lag chiller
can be started, the following conditions must be met:
1. The lag chiller status indicates it is in CCN mode and
is not in an alarm condition. If the current lag chiller is
in an alarm condition, the standby chiller becomes the
active lag chiller, if it is configured and available.
2. Lead chiller ramp loading must be complete.
3. The configured LAG START TIMER entry has elapsed.
The LAG START TIMER starts when the lead chiller
ramp loading is completed or when a lag chiller stops.
The LAG START TIMER entry is on the LEADLAG
screen, which is accessed from the EQUIPMENT
SERVICE table of the SERVICE menu.
4. Lead chiller ACTIVE DEMAND LIMIT (see the
MAINSTAT screen) value must be greater than 95% of
full load amps.
5. Lead CHILLED LIQUID TEMP must be greater than
the CONTROL POINT temperature (see the MAINSTAT screen) plus 1/2 the CHILLED LIQUID DEADBAND temperature (see the SETUP1 screen).
NOTE: The chilled liquid temperature sensor may be
the leaving chilled liquid sensor, the return liquid sensor, the common supply liquid sensor, or the common
return liquid sensor, depending on which options are
configured and enabled.
6. Lead chiller temperature pulldown rate (TEMP PULLDOWN DEG/MIN on the TEMP_CTL screen) of the
chilled liquid temperature is less than 0.5º F (0.27º C)
per minute for a cumulative duration greater than the
PULLDOWN TIMER setting in the LEADLAG
screen.
43
DEMAND LIMIT is set, the CONTROL POINT is assigned a
value of 3º F (1.67º C) less than the lead chiller’s CONTROL
POINT value to better match the lead chiller’s load level. If the
LOAD BALANCE OPTION is disabled, the ACTIVE
DEMAND LIMIT and the CONTROL POINT are forced to the
same value as the lead chiller.
AUTO RESTART AFTER POWER FAILURE — When an
Auto restart condition occurs, each chiller may have a delay
added to the start-up sequence, depending on its lead/lag
configuration. The lead chiller does not have a delay. The lag
chiller has a 45-second delay. The standby chiller has a
90-second delay. The delay time is added after the chiller liquid
flow is verified. The delay must elapse before the oil pump is
turned on. The Auto restart delay sequence occurs whether the
chiller is in CCN or LOCAL mode and is intended to stagger
the compressor motor starts. Preventing the motors from starting simultaneously helps reduce the inrush demands on the
building power system.
2. The lead chiller CHILLED LIQUID TEMP is less than
the CONTROL POINT temperature (see the MAINSTAT
screen) plus on half of the CHILLED LIQUID DEADBAND temperature (see the SETUP1 screen).
3. The configured LAG STOP TIMER entry has elapsed.
The LAG STOP TIMER starts when the lead chiller
CHILLED LIQUID TEMP is less than the chilled liquid
CONTROL POINT plus 1/2 of the CHILLED LIQUID
DEADBAND and the lead chiller compressor motor load
(PERCENT MOTOR KILOWATTS or AVERAGE LINE
CURRENT on the MAINSTAT screen) is less than the
lead chiller percent capacity.
NOTE: The use of AVERAGE LINE CURRENT or PERCENT
MOTOR KILOWATTS in the Lag chiller shutdown decision
is based on the DEMAND LIMIT SOURCE configuration in
the RAMP_DEM screen. If DEMAND LIMIT SOURCE = 0
then AVERAGE LINE CURRENT will be used. If DEMAND
LIMIT SOURCE = 1 then PERCENT MOTOR KILOWATTS
will be used.
FAULTED CHILLER OPERATION — If the lead chiller
shuts down because of an alarm (*) condition, it stops communicating to the lag and standby chillers. After 30 seconds, the
lag chiller becomes the acting lead chiller and starts and stops
the standby chiller, if necessary.
If the lag chiller goes into alarm when the lead chiller is also
in alarm, the standby chiller reverts, after 60 seconds, to a
stand-alone CCN mode of operation.
If the lead chiller is in an alarm (*) condition (as shown on
the ICVC panel), press the RESET softkey to clear the alarm.
The lead chiller is placed in CCN mode. The lead chiller
communicates and monitors the RUN STATUS of the lag and
standby chillers. If both the lag and standby chillers are
running, the lead chiller does not attempt to start and does not
assume the role of lead chiller until either the lag or standby
chiller shuts down. If only one chiller is running, the lead
chiller waits for a start request from the operating chiller. When
the configured lead chiller starts, it resumes its role as lead
chiller.
Attach to Network Device Control — The Service
menu includes the ATTACH TO NETWORK DEVICE
screen. From this screen the operator can:
• attach the ICVC to any CCN device, if the chiller has
been connected to a CCN network. This may include
other PIC-controlled chillers.
• upgrade software
Figure 25 shows the ATTACH TO NETWORK DEVICE
screen. The LOCAL parameter is always the ICVC module
address of the chiller on which it is mounted. Whenever the
controller identification of the ICVC changes, the change is reflected automatically in the BUS and ADDRESS columns for
the local device. See Fig. 19. Default address for local device is
BUS 0 ADDRESS 1.
When the ATTACH TO NETWORK DEVICE screen is
accessed, information can not be read from the ICVC on any
device until one of the devices listed on that screen is attached.
The ICVC erases information about the module to which it was
attached to make room for information on the new device.
Therefore, a CCN module must be attached when this screen is
entered.
To attach any CCN device, highlight it using the SELECT
softkey and press the ATTACH softkey. The message “UPLOADING TABLES, PLEASE WAIT” displays. The ICVC
then uploads the highlighted device or module. If the module
address cannot be found, the message “COMMUNICATION
FAILURE” appears. The ICVC then reverts back to the
ATTACH TO DEVICE screen. Try another device or check the
address of the device that would not attach. The upload process
time for each CCN module is different. In general, the uploading process takes 1 to 2 minutes. Before leaving the ATTACH
TO NETWORK DEVICE screen, select the local device. Otherwise, the ICVC will be unable to display information on the
local chiller.
If the lag chiller is the only chiller running and the lead
chiller is ready to resume its role as a lead chiller then the lag
chiller will perform a RECOVERY START REQUEST
(LL_MAINT screen). The lead chiller will start up when the
following conditions are met.
1. Lag chiller ramp loading must be complete.
2. Lag CHILLED LIQUID TEMP (MAINSTAT screen)
is greater than CONTROL POINT plus 1/2 the
CHILLED LIQUID DEADBAND temperature.
3. Lag chiller ACTIVE DEMAND LIMIT value must be
greater than 95% of full load amps.
4. Lag chiller temperature pulldown rate (TEMP PULLDOWN DEG/MIN) of the chilled liquid temperature is
less than 0.5 F (0.27 C) per minute for a cumulative
time duration greater than the PULLDOWN TIMER
setting in the lag chiller’s LEADLAG screen.
5. The standby chiller is not running as a lag chiller.
6. The configured LAG START TIMER has elapsed. The
LAG START TIMER is started when ramp loading is
completed.
LOAD BALANCING — When the LOAD BALANCE OPTION (see LEADLAG screen) is enabled, the lead chiller sets
the ACTIVE DEMAND LIMIT in the lag chiller to the lead
chiller’s AVERAGE LINE CURRENT or PERCENT MOTOR
KILOWATTS value in the POWER screen. This value has
limits of 40% to 100%. When the lag chiller ACTIVE
a23-1611
Fig. 25 — Example of Attach to Network
Device Screen
44
•
•
•
•
•
•
•
•
•
•
Alert History
Control Test
Control Algorithm Status
Equipment Configuration
VFD Config Data
Equipment Service
Time and Date
Attach to Network Device
Log Out of Device
ICVC Configuration
See Fig. 19 for additional screens and tables available from
the SERVICE screens listed above. Use the EXIT softkey to
return to the main MENU screen.
ATTACHING TO OTHER CCN MODULES — If the chiller ICVC has been connected to a CCN Network or other PIC
controlled chillers through CCN wiring, the ICVC can be used
to view or change parameters on the other controllers. Other
PIC III chillers can be viewed and set points changed (if the
other unit is in CCN control), if desired, from this particular
ICVC module.
If the module number is not valid, the “COMMUNICATION FAILURE” message will show and a new address number must be entered or the wiring checked. If the module is
communicating properly, the “UPLOAD IN PROGRESS”
message will flash and the new module can now be viewed.
Whenever there is a question regarding which module on
the ICVC is currently being shown, check the device name
descriptor on the upper left hand corner of the ICVC screen.
See Fig. 25.
When the CCN device has been viewed, the ATTACH TO
NETWORK DEVICE table should be used to attach to the PIC
that is on the chiller. Move to the ATTACH TO NETWORK
DEVICE table (LOCAL should be highlighted) and press the
ATTACH softkey to upload the LOCAL device. The ICVC
for the 23XRV will be uploaded and default screen will display.
NOTE: To prevent unauthorized persons from accessing the
ICVC service screens, the ICVC automatically signs off and
password-protects itself if a key has not been pressed for
15 minutes. The sequence is as follows. Fifteen minutes after
the last key is pressed, the default screen displays, the ICVC
screen light goes out (analogous to a screen saver), and the
ICVC logs out of the password-protected SERVICE menu.
The STATUS, SCHEDULE, and SETPOINT screens can be
accessed without the password by pressing the appropriate
softkey.
TO LOG OUT OF DEVICE — To access this screen and log
out of a network device, from the default ICVC screen, press
the MENU and SERVICE softkeys. Enter the password
and, from the SERVICE menu, highlight LOG OUT OF
NETWORK DEVICE and press the SELECT softkey. The
ICVC default screen will now be displayed.
NOTE: The ICVC will not automatically reattach to the local
module on the chiller. Press the ATTACH softkey to attach to
the LOCAL device and view the local chiller operation.
Service Operation — An overview of the tables and
screens available for the SERVICE function is shown in
Fig. 19.
TO ACCESS THE SERVICE SCREENS — When the SERVICE screens are accessed, a password must be entered.
1. From the main MENU screen, press the SERVICE
softkey. The softkeys now correspond to the numerals
1, 2, 3, 4.
HOLIDAY SCHEDULING (Fig. 26) — The time schedules
may be configured for special operation during a holiday
period. When modifying a time period, the “H” in the far right
column of the OCCPC01S, OCCPC02S or OCCPC03S time
schedule screen signifies that the period is applicable to a
holiday. (See Fig. 20.)
The TIME BROADCAST ENABLE function must be
activated for the holidays configured on the HOLIDAYS
screen to work properly. Access the BRODEF screen from the
EQUIPMENT CONFIGURATION table, highlight TIME
BROADCAST ENABLE and select ENABLE to activate
function. Note that when the chiller is connected to a CCN
network, only one chiller or CCN device can be configured as
the broadcast device. The controller that is configured as the
broadcaster is the device responsible for transmitting holiday,
time, and daylight-savings dates throughout the network.
To access the BRODEF screen, see the SERVICE menu
structure, Fig. 19.
To view or change the holiday periods for up to 18 different
holidays, perform the following operation:
1. At the Main Menu screen, press SERVICE to access
the Service menu.
2. Press the four digits of the password, one at a time. An
asterisk (*) appears as each digit is entered.
NOTE: The initial factory-set password is 1-1-1-1.
If the password is incorrect, an error message is
displayed.
If this occurs, return to Step 1 and try to access the
SERVICE screens again. If the password is correct, the
softkey labels change to:
2. If not logged on, follow the instructions for ATTACH
TO NETWORK DEVICE CONTROL or To Log Out
of Device. Once logged on, press NEXT until
EQUIPMENT CONFIGURATION is highlighted.
3. Once EQUIPMENT CONFIGURATION is highlighted, press SELECT to access.
NOTE: The SERVICE screen password can be changed by
entering the ICVC CONFIGURATION screen under
SERVICE menu. The password is located at the bottom of the
menu. Contact Carrier Service to override the ICVC password
if it is lost.
The ICVC screen displays the following list of available
SERVICE screens:
• Alarm History
4. Press NEXT until HOLIDAYS is highlighted. This is
the Holiday Definition table.
5. Press SELECT to enter the Data Table Select
screen.This screen lists 18 holiday tables.
6. Press NEXT to highlight the holiday table that is to
be viewed or changed. Each table is one holiday
45
softkey. This action returns the chiller to the start and stop
times established by the schedule.
The chiller may also be started by overriding the time
schedule. From the default screen, press the MENU and
SCHEDULE softkeys. Scroll down and select the current
schedule. Scroll down and select OVERRIDE, and set the
desired override time period.
Another condition for start-up must be met for chillers that
have the REMOTE CONTACTS OPTION on the EQUIPMENT SERVICE, OPTIONS screen set to ENABLE. For
these chillers, the REMOTE START CONTACT parameter on
the MAINSTAT screen must be CLOSED. From the ICVC
default screen, press the MENU and STATUS softkeys.
Scroll to high-light MAINSTAT and press the SELECT softkey. Scroll down the MAINSTAT screen to highlight
REMOTE START CONTACT and press the SELECT softkey. Press the CLOSE softkey to initiate the override. To end
the override, select REMOTE START CONTACT and press the
RELEASE softkey.
Once local start-up begins, the PIC III performs a series of
pre-start tests to verify that all pre-start alerts and safeties are
within the limits shown in Table 5. The RUN STATUS parameter on the MAINSTAT screen line now reads PRESTART. If a
test is not successful, the start-up is delayed or aborted. Failure
to verify any of the requirements up to this point will result in
the PIC III aborting the start and displaying the applicable
pre-start alert on the ICVC default screen. A pre-start alert does
not advance the starts in 12 hours counter. If the tests are
successful, the chilled liquid pump relay energizes, and the
MAINSTAT screen line now reads STARTUP.
Five seconds later, the condenser pump relay energizes.
Thirty seconds later the PIC III monitors the chilled liquid and
condenser liquid flow devices and waits until the LIQUID
FLOW VERIFY TIME (operator-configured, default 5 minutes)
expires to confirm flow. After flow is verified, the chilled
liquid temperature is compared to CONTROL POINT plus
1/ CHILLED LIQUID DEADBAND. If the temperature is less
2
than or equal to this value, the PIC III turns off the condenser
pump relay and goes into a RECYCLE mode.
NOTE: The 23XRV chillers are not available with factoryinstalled external chilled liquid flow or condenser liquid
flow devices. These are available as an accessory for use
with the CCM control board.
If the liquid temperature is high enough to require cooling,
the start-up sequence continues. Tower fan control is enabled
and the oil pump starts. Oil pressure is verified between 45 seconds and 5 minutes. The VFD is set to START following oil
pressure verification and the controls verify that no faults exist.
Proper compressor rotation is verified by monitoring the
discharge pressure.
The control center monitors load current to verify that the
compressor is running then steps the compressor up to target
speed. The start-to-start timer and Service On time timers are
activated when compressor operation is confirmed.
The controls will abort the start and display the applicable
pre-start alert on the ICVC if any of the conditions above are
not verified. Any fault after the startup process is complete
results in a safety shutdown, advancing the STARTS IN
12 HOURS counter by one, and display of the applicable shutdown status on the ICVC display.
Compressor ontime and service ontime timers start, and the
compressor STARTS IN 12 HOURS counter in the MAINSTAT screen and the TOTAL COMPRESSOR STARTS
counter advance by one.
period, starting on a specific date, and lasting up to
99 days.
7. Press SELECT to access the holiday table. The Configuration Select table now shows the START
MONTH, START DAY, and DURATION of the holiday period.
8. Press NEXT or PREVIOUS to highlight the START
MONTH, START DAY, and DURATION.
9. Press SELECT to modify the month, day, or duration.
10. Press INCREASE or DECREASE to change the
selected value.
11. Press ENTER to save the changes.
12. Press EXIT to return to the previous menu.
23XRPIC3
a23-1612
Fig. 26 — Example of Holiday Period Screen
START-UP/SHUTDOWN/
RECYCLE SEQUENCE (Fig. 27)
Local Start-Up — Local start-up (or a manual start-up) is
initiated by pressing the LOCAL menu softkey on the default
ICVC screen. Local start-up can proceed when the chiller
schedule indicates that the current time and date have been
established as a run time and date, and after the internal
15-minute start-to-start and the 1-minute stop-to-start inhibit
timers have expired. These timers are represented in the START
INHIBIT TIMER and can be viewed on the MAINSTAT screen
and DEFAULT screen. The timer must expire before the chiller
will start. If the timers have not expired the RUN STATUS
parameter on the MAINSTAT screen now reads TIMEOUT.
NOTE: The time schedule is said to be “occupied” if the
OCCUPIED? parameter on the MAINSTAT screen is set to
YES. For more information on occupancy schedules, see the
sections on Time Schedule Operation (page 21), Occupancy
Schedule (page 35), and To Prevent Accidental Start-Up
(page 65), and Fig. 20.
If the OCCUPIED? parameter on the MAINSTAT screen is
set to NO, the chiller can be forced to start as follows. From the
default ICVC screen, press the MENU and STATUS softkeys. Scroll to highlight MAINSTAT. Press the SELECT
softkey. Highlight and select CHILLER START/STOP. Press the
START softkey to override the schedule and start the chiller.
NOTE: The chiller will continue to run until this forced start is
released, regardless of the programmed schedule. To release
the forced start, highlight and select CHILLER START/STOP
from the MAINSTAT screen and press the RELEASE
46
When a stop signal occurs, the controls set TARGET VFD
SPEED to 0. This will cause the compressor to reduce speed to
the point where line amps equal the configured SOFT STOP
AMPS THRESHOLD. (In a recycle shut down, the compressor will probably be at or below the soft stop threshold amps
when the stop signal is received.) At that point, or one minute
after the stop signal occurs (whichever is earlier), the VFD is
set to STOP. If the STOP key is depressed a second time during
the soft stop or within one minute of the stop signal occurring,
the compressor is immediately stopped.
When the VFD is set to STOP, the compressor is turned off.
The compressor shut down is confirmed by monitoring load
amps. When the compressor shut down is verified, the oil
pump is turned off and VFD STOP is complete. After one
minute, the chilled liquid pump is turned off, unless it is a
recycle shut down. At this point, the compressor on-time and
service on-time timers are turned off, and the stop-to-start timer
is turned on.
At this time the condenser liquid pump is also shut off, provided that the entering condenser liquid temperature is 115 F
(6.1 C) or greater, and the condenser refrigerant temperature is
greater than the condenser freeze point plus 5° F (3° C). Otherwise, it remains under the control of the Condenser Pump
Control algorithm.
If the shut down is due to low evaporator refrigerant temperature, the chilled liquid pump continues to run until the
leaving chilled liquid temperature is greater than the control
point, plus 5° F (3° C).
Automatic Soft Stop Amps Threshold — When
a non-recycle, non-alarm shutdown is called for, the soft stop
feature unloads the compressor by reducing speed to the point
where load amps equal the SOFT STOP AMPS
THRESHOLD. The compressor is then turned off (see the
above sequence).
If the chiller enters an alarm state or if the compressor enters
a RECYCLE mode, the compressor deenergizes immediately.
To modify the soft stop amps threshold feature, scroll to the
OPTIONS screen on the ICVC. Use the INCREASE or
DECREASE softkey to set the SOFTSTOP AMPS THRESHOLD parameter to the percent of amps at which the motor will
shut down. Setting SOFT STOP AMPS THRESHOLD to 100%
de-activates this feature. The default setting is 100% amps (no
soft stop). The range is 40 to 100%.
a23-1613
A
— START INITIATED: Pre-start checks are made; chilled liquid pump
started
B
— Condenser liquid pump started (5 seconds after A)
C
— Liquid flows verified (30 sec to 5 minutes maximum after B)
D
— Chilled liquid temperature checked against control point; tower fan
control enabled; oil pump on.
E
— Oil pressure verified (oil pressure verified 45-300 sec after D.)
F
— VFD starts; phase reversal conditions monitored; compressor
ontime and service ontime start; 15-minute inhibit timer starts (VFD
fault tests for 15 sec after “F”)
G
— Verify average current >5% within 15 sec after VFD start, ramp to
VFD target speed.
H
— Compressor reaches target speed, chiller set to running status
I
— Ramp down until percent line current < soft stop amps threshold
(0-60 sec after I)
J
— Shutdown initiated: Target VFD speed to 0%. All load currents <5%.
K
— Oil pump relay off (1-20 sec after J)
L
— Evaporator pump deenergized (60 sec after K); condenser pump
and tower fan control may continue to operate if condenser pressure is high; evaporator pump may continue if in RECYCLE mode
or freeze protection alarm declared.
When the soft stop amps threshold feature is being applied,
a status message, “SHUTDOWN IN PROGRESS, COMPRESSOR UNLOADING” displays on the ICVC.
The soft stop amps threshold function can be terminated and
the compressor motor deenergized immediately by depressing
the STOP button twice.
Chilled Liquid Recycle Mode — The chiller may
cycle off and wait until the load increases to restart when the
compressor is running in a lightly loaded condition. This
cycling is normal and is known as “recycle.” A recycle
shutdown is initiated when any of the following conditions are
true:
1. ECL CONTROL OPTION is DISABLED (LCL
control):
The CONTROL POINT has not been increased by at
least 1° F in the last 5 min. AND LEAVING
CHILLED LIQUID temperature is less than the CONTROL POINT (MAINSTAT screen) minus 5° F.
OR LEAVING CHILLED LIQUID temperature is less
than the CONTROL POINT AND the difference
between ENTERING CHILLED LIQUID — LEAVING CHILLED LIQUID is less than RECYCLE
SHUTDOWN DELTA T and ice build is not active.
O/A — Restart permitted (both inhibit timers expired) (minimum of 15 minutes after F; minimum of 1 minute after L)
Fig. 27 — Control Sequence
Shutdown Sequence — Chiller shutdown begins if
any of the following occurs:
• the STOP button is pressed for at least one second (the
alarm light blinks once to confirm the stop command)
• a recycle condition is present (see Chilled Liquid
Recycle Mode section)
• the time schedule has gone into unoccupied mode
• the chiller protective limit has been exceeded and chiller
is in alarm
• the start/stop status is overridden to stop from the CCN
network or the ICVC
47
2. ECL CONTROL OPTION is ENABLED AND ice
build is not active (ECL control):
The CONTROL POINT has not been increased by at
least 1° F in the last 5 min. AND ENTERING
CHILLED LIQUID temperature is less than the CONTROL POINT minus 5° F OR ENTERING CHILLED
LIQUID temperature is less than the CONTROL
POINT AND the difference between ENTERING
CHILLED LIQUID — LEAVING CHILLED LIQUID
is less than RECYCLE SHUTDOWN DELTA T.
3. The LEAVING CHILLED LIQUID temperature is less
than the EVAP REFRIG TRIPPOINT plus 3° F.
(NOTE: Refer to Refrigerant Low Temperature
Override)
Whenever recycle shutdown is active the RUN
STATUS shall be “Recycle”.
When the chiller is in RECYCLE mode, the chilled liquid
pump relay remains energized so the chilled liquid temperature
can be monitored for increasing load. The recycle control uses
RECYCLE CONTROL RESTART DELTA T to check when the
compressor should be restarted. This is an operator-configured
function which defaults to 5º F (3º C). This value can be
viewed or modified on the SETUP1 table. The compressor will
restart when the chiller is:
• in LCL CONTROL (ECL CONTROL OPTION
DISABLED) and the LEAVING CHILLED LIQUID
temperature is greater than the CONTROL POINT plus
the RECYCLE CONTROL RESTART DELTA T.
• in ECL CONTROL and the ENTERING CHILLED
LIQUID temperature is greater than the CONTROL
POINT plus the RECYCLE CONTROL RESTART
DELTA T.
Once these conditions are met, the compressor initiates a
start-up with a normal start-up sequence.
An alert condition may be generated if 5 or more recycle
start-ups occur in less than 4 hours. Excessive recycling can
reduce chiller life; therefore, compressor recycling due to
extremely low loads should be reduced.
To reduce compressor recycling, use the time schedule to
shut the chiller down during known low load operation periods,
or increase the chiller load by running the fan systems. If the
hot gas bypass is installed, adjust the values to ensure that hot
gas is energized during light load conditions. Increase the
RECYCLE CONTROL RESTART DELTA T on the SETUP1
table to lengthen the time between restarts.
The chiller should not be operated below design minimum
load without a hot gas bypass installed.
Equipment Required
•
•
•
•
•
•
•
•
T30 hexalobular socket screw driver to remove control
center door shipping brackets
mechanic’s tools (refrigeration)
digital volt-ohmmeter (DVM)
clamp-on ammeter
electronic leak detector
absolute pressure manometer or wet-bulb vacuum indicator (Fig. 28)
500-v insulation tester (megohmmeter) for compressor
motors with nameplate voltage of 600 v or less
Reliance LCD OIM (operator interface module)
(optional)
Using the Optional Storage Tank and Pumpout System — Refer to Chillers with Storage Tanks sec-
tion, page 70 for pumpout system preparation, refrigerant
transfer, and chiller evacuation.
Remove Shipping Packaging — Remove any packaging material from the control center, oil pump, VFD cooling
solenoid, HGBP solenoid, oil reclaim actuator, oil heater terminal boxes, and relief valves.
Open Oil Circuit Valves — Check to ensure the oil filter isolation valves (Fig. 8) are open by removing the valve cap
and checking the valve stem.
Oil Charge — The oil charge for the 23XRV chiller is split
between the cooler and the oil vaporizer:
Frame
Size
3
4
5
Cooler
Charge
Oil Sump
Charge
Total
1 gal.(3.8 L)
6.5 gal.(24.6 L)
7.5 gal.
(28.4 L)
The chiller is shipped with its oil charge. The oil level in the
vaporizer will initially be in the center of the oil sump sight
glass. This level will vary depending on the amount of refrigerant that has been absorbed by the oil and the operating
conditions of the chiller. Normal oil levels will vary from the
top of the strainer housing sight glass to above the top of the oil
sump sight glass.
If oil is added, it must conform to Carrier’s specification for
screw compressor use as described in the Oil Specification
section. Charge the oil through the oil charging valve located
near the bottom of the oil strainer housing. The oil must be
pumped from the oil container through the charging valve due
to the higher refrigerant pressure. The pumping device must be
able to lift from 0 to 200 psig (1379 kPa) or above unit
pressure. Oil should only be charged or removed when the
chiller is shut down.
Safety Shutdown — A safety shutdown is identical to a
manual shutdown with the exception that, during a safety
shutdown, the ICVC displays the reason for the shutdown, the
alarm light blinks continuously, and the spare alarm contacts
are energized.
After a safety shutdown, the RESET softkey must be
pressed to clear the alarm. If the alarm condition is still present,
the alarm light continues to blink. Once the alarm is cleared,
the operator must press the CCN or LOCAL softkeys to
restart the chiller.
Tighten All Gasketed Joints — Gaskets normally
relax by the time the chiller arrives at the jobsite. Tighten all
gasketed joints to ensure a leak-tight chiller. See Table 8 for
waterbox torque specifications.
Table 8 — Waterbox Bolt Torque
COOLER or
CONDENSER
BEFORE INITIAL START-UP
FRAME 3
Job Data Required
• list of applicable design temperatures and pressures
(product data submittal)
• chiller certified prints
• starting equipment details and wiring diagrams
• diagrams and instructions for special controls or options
• 23XRV Installation Instructions
• pumpout unit instructions
FRAME 4
FRAME 5
48
NOMINAL
BOLT SIZE
5/ -11
8
3/ -10
4
5/ -11
8
3/ -10
4
7/ - 9
8
5/ -11
8
3/ -10
4
7/ - 9
8
TORQUE
ft-lb
105-150
175-250
105-150
175-250
265-380
105-150
175-250
265-380
N-m
142-203
237-339
142-203
237-339
359-515
142-203
237-339
359-515
Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 35 psig (241 kPa). Charge as
a gas only, with the cooler and condenser pumps running,
until this pressure is reached, using PUMPDOWN and
TERMINATE PUMPDOWN MODE on the ICVC. Flashing of liquid refrigerant at low pressures can cause tube
freeze-up and considerable damage.
2.
a19-658
Fig. 28 — Typical Wet-Bulb Type
Vacuum Indicator
Check Chiller Tightness — Figure 29 outlines the
proper sequence and procedures for leak testing.
23XRV chillers are shipped with a full refrigerant and oil
charge. Units may be ordered with the refrigerant shipped
separately, and a 15 psig (103 kPa) nitrogen-holding charge in
each vessel. To determine if there are any leaks, the chiller
should be charged with a refrigerant tracer. Use an electronic
leak detector to check all flanges and solder joints after the
chiller is pressurized. If any leaks are detected, follow the leak
test procedure.
If the chiller is spring isolated, keep all springs blocked in
both directions to prevent possible piping stress and damage
during the transfer of refrigerant from vessel to vessel during
the leak test process, or any time refrigerant is being transferred. Adjust the springs when the refrigerant is in operating
condition and the liquid circuits are full.
3.
4.
Refrigerant Tracer — Carrier recommends the use of an
environmentally acceptable refrigerant tracer for leak testing
with an electronic detector or halide torch.
Ultrasonic leak detectors can also be used if the chiller is
under pressure.
5.
6.
Do not use air or oxygen as a means of pressurizing
the chiller. Mixtures of HFC-134a and air can undergo
combustion.
Leak Test Chiller — Due to regulations regarding refrigerant emissions and the difficulties associated with separating
contaminants from refrigerant, Carrier recommends the following leak test procedures. See Fig. 29 for an outline of the leak
test procedures. Refer to Fig. 30-33 during pumpout procedures. See the Pumpout and Refrigerant Transfer Procedures
Section on page 69. Refer to Tables 9A and 9B for temperature/pressure relationships for HFC-134a refrigerant.
1. If the pressure readings are normal for chiller
condition:
a. Evacuate the holding charge from the vessels, if
present.
b. Raise the chiller pressure, if necessary, by adding
refrigerant until pressure is at equivalent saturated
pressure for the surrounding temperature.
7.
49
c. Leak test chiller as outlined in Steps 3 - 7.
If the pressure readings are abnormal for chiller
condition:
a. Prepare to leak test chillers shipped with refrigerant. If chiller is shipped with refrigerant, proceed
to Step 3.
b. Check for large leaks by connecting a nitrogen
bottle and raising the pressure to 30 psig
(207 kPa). Soap test all joints. If the test pressure
holds for 30 minutes, prepare the test for small
leaks (Steps 2g - h).
c. Plainly mark any leaks which are found.
d. Release the pressure in the system.
e. Repair all leaks.
f. Retest only those joints that were repaired.
g. After successfully completing the test for large
leaks, remove as much nitrogen, air, and moisture
as possible, given the fact that small leaks may be
present in the system. This can be accomplished
by following the dehydration procedure, outlined
in the Chiller Dehydration section, page 55.
h. Slowly raise the system pressure to normal operating pressures for the refrigerant used in the chiller.
Proceed with the test for small leaks (Steps 3-7).
Check the chiller carefully with an electronic leak
detector or halide torch.
Leak Determination — If an electronic leak detector
indicates a leak, use a soap bubble solution, if possible,
to confirm. Total all leak rates for the entire chiller.
Leakage at rates greater than 1 lb/year (0.45 kg/year)
for the entire chiller must be repaired. Note total
chiller leak rate on the start-up report.
If no leak is found during initial start-up procedures,
complete the transfer of refrigerant gas from the
storage tank to the chiller. Retest for leaks.
If no leak is found after a retest
a. Transfer the refrigerant to the storage tank and
perform a standing vacuum test as outlined in the
Chiller Dehydration section, page 55.
b. If the chiller fails this test, check for large leaks
(Step 2b).
c. Dehydrate the chiller if it passes the standing
vacuum test. Follow the procedure in the
Chiller Dehydration section. Charge chiller with
refrigerant.
If a leak is found, pump the refrigerant back into the
storage tank, or if isolation valves are present, pump
into the vessel that is not leaking.
Transfer the refrigerant until chiller pressure is at least
equal to the pressure specified by the EPA under
40 CFR Part 82.
Repair the leak and repeat the procedure, beginning
from Step 2h to ensure a leaktight repair. If chiller is
opened to the atmosphere for an extended period,
evacuate it before repeating leak test.
a23-1614
50
Fig. 29 — 23XRV Leak Test Procedure
3/8" MALE FLARE
RELIEF VALVE CONN.
W
LEVEL GAGE
0' - 9 "
[229mm]
TYPICAL
1/2" DIA. K.O.
ELECTRICAL CONN.
(PUMPOUT POWER)
0' - 5 1/2"
[140mm]
D
E
(2) 1" NPT RELIEF
VALVE OUTLET (SEE FIELD
INSTALLATION NOTES)
PRESSURE GAGE
R
1' - 7 "
[483mm]
T
0' - 5 7/8 "
[149mm]
a23-1541
B
TOP VIEW
1/2" MALE FLARE
VAPOR CONN.
3/4" NPT
PUMPOUT CONDENSER
WATER INLET CONN.
NOTES:
1.
3/4" NPT
PUMPOUT CONDENSER
WATER OUTLET CONN.
ELECTRICAL SERVICE
ACCESS SPACE
20 3/4" X 8 3/4" X 4 1/2"
(BOTH SIDES)
Denotes center of gravity.
2. Dimensions in [
] are in
millimeters.
3. The weights and center of
gravity values given are for an
empty storage tank.
4. For additional information on
the pumpout unit, see certified
drawings.
5. Conduit knockout is located on
the side of the control box.
6. 28 cubic ft storage tank
weight: 2334 lb (1059 kg).
7. 52 cu ft storage tank weight:
3414 lb (1549 kg).
VAPOR
J
L
K
F
1" NPT
LIQUID CONN.
V
0'- 9"
[229mm]
TYPICAL
0'- 9 7/8"
[249mm]
U
N
M
G
a23-1542
A
FRONT VIEW
DIMENSIONS
1'-0 3/4"
[324mm]
0'- 7 15/16"
[202mm]
(FARSIDE)
ENGLISH (ft-in.)
3/8" MALE FLARE
RELIEF VALVE CONN.
0'- 2 3/4"
[70mm]
1/2" DIA. K.O.
ELECTRICAL CONN.
(PUMPOUT POWER)
(FAR SIDE)
H
C
TANK
SIZE
0428
D
E
F
G
10- 5
4-41/4
2-43/4
1-23/8
3-11/4
6-43/16
3-113/
0452
14-111/4 14- 41/2 4-81/4
2-81/2
1-41/4
3-41/2
7-21/4
A
B
9-10
C
H
J
K
8
3-47/8
2-99/16
4- 31/4
3-83/4
3-17/16
TANK
SIZE
0428
L
M
N
P
R
S
T
V
W
3-45/8
0-31/2
4- 91/2
1-77/8
2-03/8
3-9
5-01/4
2-5
2-97/8
2-53/4
0452
3-81/2
0-33/8
6-115/8
1-83/4
2-05/8
4-1
5-01/2
2-51/4
2-101/8
2-6
U
SI (mm)
S
P
0'- 10"
[254mm]
0'- 3 1/4"
[83mm]
a23-1543
TANK
SIZE
0428
0452
A
B
C
D
E
F
G
H
J
K
3175
4553
2997
4381
1327
1429
730
826
365
413
946
1029
1935
2191
1203
1302
1038
1137
852
951
TANK
SIZE
0428
0452
L
M
N
P
R
S
T
U
V
W
1032
1130
89
86
1451
2124
505
527
619
625
1143
1225
1530
1537
737
742
860
867
756
762
LEFT SIDE VIEW
Fig. 30 — Optional Pumpout Unit and Storage Tank
51
RATED DRY WEIGHT AND REFRIGERANT CAPACITY
ENGLISH (lb)
TANK
SIZE
TANK OD
(in.)
0428
0452
24.00
27.25
DRY
WEIGHT*
(lb)
2334
3414
R-134a MAXIMUM REFRIGERANT CAPACITY (lb)
ANSI/ASHRAE 15
UL 1963
1860
3563
1716
3286
SI (kg)
TANK
SIZE
TANK OD
(mm)
0428
0452
610
692
DRY
WEIGHT*
(kg)
1059
1549
R-134a MAXIMUM REFRIGERANT CAPACITY (kg)
ANSI/ASHRAE 15
UL 1963
844
1616
778
1491
LEGEND
ANSI
— American National Standard Institute
ASHRAE — American Society of Heating, Refrigeration,
and Air Conditioning Engineers
OD
— Outside Diameter
UL
— Underwriters Laboratories
*The above dry weight includes the pumpout condensing unit weight of 164 lb (75 kg).
COOLER INLET
ISOLATION VALVE 11
COOLER REFRIGERANT
PUMPOUT VALVE 7
COOLER CHARGING
VALVE 1b
COOLER
CONDENSER
CHARGING
VALVE 1a
CONTROL CENTER
SHIPPING BRACE
(REMOVE PRIOR TO
START-UP)
DISCHARGE ISOLATION
VALVE (OPTIONAL)
PRESSURE
RELIEF SAFETY
VALVE
10
PUMPOUT
COMPRESSOR
= SERVICE VALVE ON
CHILLER (FIELD
SUPPLIED)
= MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND
STORAGE TANK FOR SERVICE AND OPERATION WORK.
= SERVICE VALVE ON
PUMPOUT UNIT
a23-1634
STORAGE
TANK LIQUID
VALVE
OIL
SEPARATOR
PUMPOUT
CONDENSER
2
3
4
5
PUMPOUT
CONDENSER
WATER SUPPLY
AND RETURN
6 STORAGE TANK
VAPOR VALVE
Fig. 31 — Optional Pumpout System Piping Schematic with Storage Tank
(Configured to Push Liquid into Storage Tank)
52
COOLER INLET
ISOLATION VALVE 11
COOLER REFRIGERANT
PUMPOUT VALVE 7
COOLER CHARGING
VALVE 1b
COOLER
USE CONDENSER
CHARGING
VALVE TO ADD
CHARGE 1a
CONTROL CENTER
DISCHARGE ISOLATION
VALVE (OPTIONAL)
SHIPPING BRACE
(REMOVE PRIOR TO
START-UP)
PRESSURE
RELIEF SAFETY
VALVE
10
PUMPOUT
COMPRESSOR
= SERVICE VALVE ON
CHILLER (FIELD
SUPPLIED)
= MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND
STORAGE TANK FOR SERVICE AND OPERATION WORK.
= SERVICE VALVE ON
PUMPOUT UNIT
a23-1637
STORAGE
TANK LIQUID
VALVE
OIL
SEPARATOR
PUMPOUT
CONDENSER
2
3
4
5
PUMPOUT
CONDENSER
WATER SUPPLY
AND RETURN
6 STORAGE TANK
VAPOR VALVE
Fig. 32 — Optional Pumpout System Piping Schematic with Storage Tank
(Configured to Pull Vapor out of Chiller or to Charge Chiller from Storage Tank)
COOLER INLET
ISOLATION VALVE 11
COOLER REFRIGERANT
PUMPOUT VALVE 7
COOLER CHARGING
VALVE 1b
COOLER
CONDENSER
CHARGING
VALVE 1a
CONTROL CENTER
SHIPPING BRACE
(REMOVE PRIOR TO
START-UP)
DISCHARGE ISOLATION
VALVE (OPTIONAL)
PRESSURE
RELIEF SAFETY
VALVE
1a
SERVICE VALVE
OIL
SEPARATOR
= SERVICE VALVE ON
PUMPOUT UNIT
= SERVICE VALVE ON
CHILLER
PUMPOUT
CONDENSER
PUMPOUT
COMPRESSOR
a23-1638
2
3
4
5
PUMPOUT
CONDENSER
WATER SUPPLY
AND RETURN
Fig. 33 — Optional Pumpout System Piping Schematic without Storage Tank
(Configured to Store Refrigerant in Cooler or Condenser)
53
Table 9A — HFC-134a Pressure — Temperature (F)
TEMPERATURE, F
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
Table 9B — HFC-134a Pressure — Temperature (C)
PRESSURE (psig)
6.50
7.52
8.60
9.66
10.79
11.96
13.17
14.42
15.72
17.06
18.45
19.88
21.37
22.90
24.48
26.11
27.80
29.53
31.32
33.17
35.08
37.04
39.06
41.14
43.28
45.48
47.74
50.07
52.47
54.93
57.46
60.06
62.73
65.47
68.29
71.18
74.14
77.18
80.30
83.49
86.17
90.13
93.57
97.09
100.70
104.40
108.18
112.06
116.02
120.08
124.23
128.47
132.81
137.25
141.79
146.43
151.17
156.01
160.96
166.01
171.17
176.45
181.83
187.32
192.93
198.66
204.50
210.47
216.55
222.76
229.09
TEMPERATURE, C
-18.0
-16.7
-15.6
-14.4
-13.3
-12.2
-11.1
-10.0
-8.9
-7.8
-6.7
-5.6
-4.4
-3.3
-2.2
-1.1
0.0
1.1
2.2
3.3
4.4
5.0
5.6
6.1
6.7
7.2
7.8
8.3
8.9
9.4
10.0
11.1
12.2
13.3
14.4
15.6
16.7
17.8
18.9
20.0
21.1
22.2
23.3
24.4
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
54
PRESSURE (kPa)
44.8
51.9
59.3
66.6
74.4
82.5
90.8
99.4
108.0
118.0
127.0
137.0
147.0
158.0
169.0
180.0
192.0
204.0
216.0
229.0
242.0
248.0
255.0
261.0
269.0
276.0
284.0
290.0
298.0
305.0
314.0
329.0
345.0
362.0
379.0
396.0
414.0
433.0
451.0
471.0
491.0
511.0
532.0
554.0
576.0
598.0
621.0
645.0
669.0
694.0
720.0
746.0
773.0
800.0
828.0
857.0
886.0
916.0
946.0
978.0
1010.0
1042.0
1076.0
1110.0
1145.0
1180.0
1217.0
1254.0
1292.0
1330.0
1370.0
1410.0
1451.0
1493.0
1536.0
1580.0
8. If the reading continues to change after several attempts,
perform a leak test up to the maximum 160 psig
(1103 kPa) pressure. Locate and repair the leak, and
repeat dehydration.
Chiller Dehydration — Dehydration is recommended if
the chiller has been open for a considerable period of time, if
the chiller is known to contain moisture, or if there has been a
complete loss of chiller holding charge or refrigerant pressure.
Inspect Liquid Piping — Refer to piping diagrams
provided in the certified drawings and the piping instructions in
the 23XRV Installation Instructions manual. Inspect the piping
to the cooler and condenser. Be sure that the flow directions are
correct and that all piping specifications have been met.
Piping systems must be properly vented with no stress on
waterbox nozzles and covers. Liquid flows through the cooler
and condenser must meet job requirements. Measure the pressure drop across the cooler and the condenser.
Do not start or megohm-test the compressor motor, even
for a rotation check, if the chiller is under dehydration vacuum. Insulation breakdown and severe damage may result.
Dehydration can be done at room temperatures. Using a
cold trap (Fig. 34) may substantially reduce the time required
to complete the dehydration. The higher the room temperature,
the faster dehydration takes place. At low room temperatures, a
very deep vacuum is required to boil off any moisture. If low
ambient temperatures are involved, contact a qualified service
representative for the dehydration techniques required.
Perform dehydration as follows:
1. Disconnect power from the VFD before placing the
chiller under a vacuum.
2. Connect a high capacity vacuum pump (5 cfm [.002 m3/s]
or larger is recommended) to the cooler or condenser
charging valve (Fig. 2 and 3). Tubing from the pump to
the chiller should be as short in length and as large in
diameter as possible to provide least resistance to gas
flow.
3. Use an absolute pressure manometer or a wet bulb
vacuum indicator to measure the vacuum. Open the
shutoff valve to the vacuum indicator only when taking a
reading. Leave the valve open for 3 minutes to allow the
indicator vacuum to equalize with the chiller vacuum.
4. If the entire chiller is to be dehydrated, open all isolation
valves (if present).
5. With the chiller ambient temperature at 60 F (15.6 C) or
higher, operate the vacuum pump until the manometer
reads 29.8 in. Hg vacuum, referenced to 30 inches of
mercury barometric pressure (0.1 psia) (–100.6 kPa) or a
vacuum indicator reads 35 F (1.7 C). Operate the pump
an additional 2 hours.
Do not apply a greater vacuum than 29.82 in. Hg vac
(757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb
vacuum indicator. At this temperature and pressure,
isolated pockets of moisture can turn into ice. The slow
rate of evaporation (sublimation) of ice at these low
temperatures and pressures greatly increases dehydration
time.
6. Valve off the vacuum pump, stop the pump, and record
the instrument reading.
7. After a 2-hour wait, take another instrument reading. If
the reading has not changed, dehydration is complete. If
the reading indicates vacuum loss, repeat Steps 4 and 5.
Liquid must be clean and treated to ensure proper chiller
performance and to reduce the potential of tube damage
due to corrosion, scaling, or erosion. Carrier assumes no
responsibility for chiller damage resulting from untreated
or improperly treated cooler or condenser liquid.
Check Optional Pumpout Compressor Liquid
Piping — If the optional pumpout storage tank and/or
pumpout system are installed, check to ensure the pumpout
condenser liquid has been piped in. Check for field-supplied
shutoff valves and controls as specified in the job data. Check
for refrigerant leaks on field-installed piping. See Fig. 30-33.
Check Relief Valves — Be sure the relief valves have
been piped to the outdoors in compliance with the latest edition
of ANSI/ASHRAE Standard 15 and applicable local safety
codes. Piping connections must allow for access to the valve
mechanism for periodic inspection and leak testing.
The 23XRV relief valves are set to relieve at the 185 psig
(1276 kPa) chiller design pressure.
Identify the VFD — The LiquiFlo™ 2.0 AC drive is a
PWM (Pulse Width Modulated), liquid-cooled drive that
provides vector and general purpose regulation for a wide
range of applications. Identify the drive from the Drive Part
Number on the drive’s nameplate and the model number
matrix in Fig. 35 and 36.
a23-1553
a19-661
Fig. 34 — Dehydration Cold Trap
Fig. 35 — VFD Nameplate
55
LF20
0608CC
R
LF20 = LiquiFlo 2.0
Continuous Ampere Rating
and Frame Size
Coolant Method
R = Refrigerant R134a
a23-1629
Fig. 36 — Identifying the Drive Model Number
The control center is designed to operate in the following
environmental conditions:
DC bus capacitors retain hazardous voltage after input
power has been disconnected. After disconnecting input
power, wait 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to
ensure the DC capacitors are completely discharged before
touching any internal components. Failure to observe this
precaution could result in severe bodily injury or loss of
life.
CONDITION
SPECIFICATION
Ambient Temperature
(outside NEMA 1 enclosure)
32 to 122 F (0° to 50 C)
Storage Temperature
(ambient)
-40 to 149 F (-40 to 65 C)
Humidity
5% to 95%
(non-condensing)
IDENTIFYING THE DRIVE BY PART NUMBER —
Each AC drive can be identified by its assembly number. See
Fig. 36. This number appears on the shipping label and on the
drive’s nameplate. LiquiFlo 2.0 AC drives comprise an input
components section and a power module section.
Each LiquiFlo™ 2.0 AC power module can be identified by
its model number. See Fig. 36. This number appears on the
shipping label and on the power module’s nameplate. Power
ratings are provided in Table 10.
The drive can operate at and maintain zero speed. The user
is responsible for assuring safe conditions for operating
personnel by providing suitable guards, audible or visual
alarms, or other devices to indicate that the drive is operating or may operate at zero speed. Failure to observe this
precaution could result in severe bodily injury or loss of
life.
The drive contains ESD (Electrostatic Discharge) sensitive
parts and assemblies. Static control precautions are
required when installing, testing, servicing, or repairing the
drive. Erratic machine operation and damage to, or destruction of equipment can result if this procedure is not
followed.
Table 10 — Drive Assembly and Power Module Ratings
PART NUMBER
FRAME
SIZE
23XRA2AA___________
AA
23XRA2BA___________
BA
23XRA2BB___________
BB
23XRA2CC___________
CC
MAX OUTPUT
CURRENT*
AT 4 kHz
(AMPS)
ENCLOSURE
RATING
NAMEPLATE
INPUT
VOLTAGE (V)
MAX INPUT
CURRENT
(AMPS)
440
442
NEMA 1
380, 400,
416, 460
±10%
520
442
520
520
608
608
*110% output current capability for 1 minute. 150% output current capability for 5 sec.
56
9. Check that the incoming power is within ± 10% of chiller
nameplate voltage.
10. All wiring should be installed in conformance with the
applicable local, national, and international codes (for
example, NEC/CEC). Verify that a properly sized ground
wire is installed and a suitable earth ground is used.
Check for and eliminate any grounds between the power
leads. Verify that all ground leads are unbroken.
Check Control Center
BE AWARE that certain automatic start arrangements can
engage the VFD. Open the disconnect ahead of the control
center in addition to shutting off the chiller or pump.
Inspect Wiring
The main disconnect on the control center may not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter.
Do not check the voltage supply without proper equipment
and precautions. Serious injury may result. Follow power
company recommendations.
Input Power Wiring — All wiring should be installed in
conformance with applicable local, national, and international
codes. Use grommets, when hubs are not provided, to guard
against wire chafing.
Use the following steps to connect AC input power to the
main input circuit breaker and ground leads to the ground lug.
1. Turn off, lockout, and tag the input power to the drive.
2. Remove the input power wiring panel from the top of the
control center and drill the required number of openings
in the input power wiring panel. Take care that metal
chips do not enter the VFD enclosure.
3. Wire the AC input power leads and ground leads by
routing them through the opening in the top of the control
center to the main input circuit breaker.
Do not apply any kind of test voltage, even for a rotation
check, if the chiller is under a dehydration vacuum. Insulation breakdown and serious damage may result.
1. Examine the wiring for conformance to the job wiring
diagrams and all applicable electrical codes. Confirm that
there is at least a 6 in. clearance surrounding the control
center louvers. Use an inspection mirror to visually
inspect the top of the power module to confirm that no
debris has fallen inside of it.
2. Connect a voltmeter across the power wires to the VFD
and measure the phase to phase and phase to ground
voltage. Compare this reading to the voltage rating on the
compressor and starter nameplates.
3. Compare the ampere ratings on the Machine Electrical
Data Nameplate. LOCKED ROTOR AMPS should be
equal to RATED LINE AMPS. OVERLOAD TRIP
AMPS should be equal to 1.08 X RATED LINE AMPS.
4. The control center must be wired to components and
terminals required for PIC III refrigeration control. Check
line side power and for control components shown on the
Certified Prints. The control center must share control of
cooler and condenser liquid pumps and cooling tower
fans.
5. Check the phase to phase and phase to ground line
voltage to the optional pumpout compressor. Compare
voltages against nameplate values. Refer to Fig. 37.
6. Ensure that fused disconnects or circuit breakers have
been supplied to the control center and optional pumpout
unit.
7. Ensure all electrical equipment and controls are properly
grounded in accordance with the job drawings, certified
drawings, and all applicable electrical codes.
8. Ensure the customer's contractor has verified proper operation of the pumps, cooling tower fans, and associated
auxiliary equipment. This includes ensuring motors are
properly lubricated and have proper electrical supply and
proper rotation.
9. Tighten all wiring connections on the high and low voltage terminal blocks in the control center enclosure above
and below the control panel.
10. Inspect the control panel in the control center enclosure to
ensure that the contractor has used the knockouts to feed
the wires into the back of the control panel. Wiring
through the top of the control center can cause debris to
fall into the power module. Clean and inspect the interior
of the control center if this has occurred. Contact Carrier
Service before applying power if debris may have fallen
inside of the power module.
Do not route control wiring carrying 30 v or less within a
conduit carrying 50 v or higher. Failure to observe this precaution could result in electromagnetic interference in the
control wiring.
4. Connect the three-phase AC input power leads (per job
specification) to the appropriate input terminals of the circuit breaker.
5. Tighten the AC input power terminals and lugs to the
proper torque as specified on the input circuit breaker.
6. Connect and tighten the ground leads to the ground lug.
Checking the Installation — Use the following instructions to verify the condition of the installation:
1. Turn off, lockout, and tag the input power to the drive.
Wait a minimum of 5 minutes for the DC bus to
discharge.
2. Verify that there is no voltage at the input terminals (L1,
L2 and L3) of the power module or main circuit breaker.
3. Verify that the status LEDs on the DPI Communications
Interface Board are not lit. The location of the DPI
Communications Interface Board is shown in Fig. 13.
4. Remove any debris, such as metal shavings, from the
enclosure.
5. Check that there is adequate clearance around the
machine.
6. Verify that the wiring to the terminal strip and the AC
input power terminals is correct. Verify that all of the
VFD power module circuit board connectors are fully
engaged and secured in place.
7. Check that the wire size is within terminal specifications
and that the wires are tightened properly.
8. Check that specified branch circuit protection is installed
and correctly rated.
57
b. Divide the 60-second resistance reading by the
10-second reading. The ratio, or polarization
index, must be one or higher. Both the 10 and
60-second readings must be at least 50 megohms.
c. If the readings are unsatisfactory, repeat the test
with the motor leads disconnected from the motor.
Satisfactory readings in this second test indicate
the fault is in the power leads.
Carrier Comfort Network® Interface — The Carrier
Comfort Network (CCN) communication bus wiring is
supplied and installed by the electrical contractor. It consists of
shielded, 3-conductor cable with drain wire.
The system elements are connected to the communication
bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the
positive pins of the system element on either side of it. The
negative pins must be wired to the negative pins. The signal
ground pins must be wired to the signal ground pins. See the
23XRV Installation Instructions.
NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual
conductors must be insulated with PVC, PVC/nylon, vinyl,
Teflon, or polyethylene. An aluminum/polyester 100% foil
shield and an outer jacket of PVC, PVC/nylon, chrome vinyl,
or Teflon with a minimum operating temperature range of –4 F
to 140 F (–20 C to 60 C) is required. See table below for cables
that meet the requirements.
MANUFACTURER
Alpha
American
Belden
Columbia
CABLE NO.
2413 or 5463
A22503
8772
02525
When connecting the CCN communication bus to a system
element, a color code system for the entire network is recommended to simplify installation and checkout. The following
color code is recommended:
a23-1555
Fig. 37 — Machine Electrical Data Nameplate
SIGNAL TYPE
Do not apply power unless a qualified Carrier technician is
present. Electrical shock could cause serious personal
injury or death.
11. Apply power to the control center. Go to the ICVC
and access the MENU>SERVICE>VFD CONFIG
DATA>VFD_CONF screen. Confirm that the parameters
entered in VFD_CONF match the information on the
Machine Nameplate and Sales Requisition. Confirm that
the serial numbers on the chiller, Machine Nameplate,
and Sales Requisition are consistent.
CCN BUS CONDUCTOR
INSULATION COLOR
ICVC PLUG
J1
PIN NO.
+
Red
1
Ground
White or Clear
2
–
Black
3
Power Up the Controls and Check the Oil
Heater — Ensure that an oil level is visible in the oil sump
before energizing the controls. A separate 15A Control Power
Circuit Breaker in the control center energizes the oil heater
and the control circuit. When first powered, the ICVC should
display the default screen within a short period of time.
The oil heater is energized when power is applied to the
control circuit. This should be done several hours before startup to minimize oil-refrigerant migration. The oil heater is
controlled by the PIC III and is powered through a contactor on
the power panel. This arrangement allows the heater to
energize when the main motor circuit breaker is off for service
work or extended shutdowns. The oil heater relay status (OIL
HEATER RELAY) can be viewed on the COMPRESS table on
the ICVC. Oil sump temperature can be viewed on the ICVC
default screen.
SOFTWARE VERSION — The software part number is
labeled on the backside of the ICVC module. The software
version also appears on the ICVC CONFIGURATION screen
as the last two digits of the software part number.
Ground Fault Troubleshooting — Use this proce-
dure only if ground faults are declared:
Disconnect the motor leads from the control center before a
motor insulation test is performed. The voltage generated
from the testing equipment will damage the VFD.
Test the compressor motor and its power lead insulation resistance with a 500 V insulation tester such as a megohmmeter.
With the tester connected to the motor leads, take 10 second
and 60 second megaohm readings as follows:
a. Tie terminals 1, 2, and 3 together and test between
the grouped motor terminals and ground.
58
TO CHANGE THE PASSWORD — The password may be
changed from the ICVC CONFIGURATION screen.
1. Press the MENU and SERVICE softkeys. Enter the
current password and highlight ICVC CONFIGURATION. Press the SELECT softkey. Only the last 6
entries on the ICVC CONFIG screen can be changed:
BUS #, ADDRESS #, BAUD RATE, US IMP/METRIC,
PASSWORD, and LID LANGUAGE.
Software Configuration
Do not operate the chiller before the control configurations
have been checked in the ICVC and a Control Test has
been satisfactorily completed. Protection by safety controls
cannot be assumed until all control configurations have
been confirmed.
2. Use the ENTER softkey to scroll to PASSWORD. The
first digit of the password is highlighted on the screen.
As the 23XRV unit is configured, all configuration settings
should be written down. A log, such as the one shown on pages
CL-1 to CL-11, provides a convenient list for configuration
values.
It is recommended that all control configuration tables be
uploaded via service tool and stored for reference when the
software configuration is complete.
3. To change the digit, press the INCREASE or
DECREASE softkey. When the desired digit is seen,
press the ENTER softkey.
4. The next digit is highlighted. Change it, and the third
and fourth digits in the same way the first was
changed.
Input the Design Set Points — Access the ICVC
SET POINT screen and view/modify the BASE DEMAND
LIMIT set point, and either the LCL SET POINT or the ECL
SET POINT. The PIC III can control a set point to either the
leaving or entering chilled liquid. This control method is set in
the EQUIPMENT SERVICE (TEMP_CTL) table. The default
setting of ECL CONTROL OPTION is DSABLE so the
PIC III will control the leaving chilled liquid temperature.
5. After the last password digit is changed, the ICVC
goes to the LID LANGUAGE parameter. Press the
EXIT softkey to leave that screen and return to the
SERVICE menu.
Input the Local Occupancy Schedule
(OCCPC01S) — Access the schedule OCCPC01S screen
Be sure to remember the password. Retain a copy
for future reference. Without the password, access to the
SERVICE menu will not be possible unless the
ICVC_PWD menu on the STATUS screen is accessed by a
Carrier representative.
on the ICVC and set up the occupied time schedule according
to the customer’s requirements. If no schedule is available, the
default is factory set for 24 hours occupied, 7 days per week
including holidays.
For more information about how to set up a time schedule,
see the Time Schedule Operation section, page 21.
The CCN Occupied Schedule (OCCPC03S) should be configured if a CCN system is being installed or if a secondary
time schedule is needed.
NOTE: The default CCN Occupied Schedule OCCPC03S is
configured to be unoccupied.
TO CHANGE THE ICVC DISPLAY FROM ENGLISH TO
METRIC UNITS — By default, the ICVC displays information in English units. To change to metric units, access the
ICVC CONFIGURATION screen:
1. Press the MENU and SERVICE softkeys. Enter the
password and highlight ICVC CONFIGURATION.
Press the SELECT softkey.
Input Service Configurations — The following configurations require the ICVC screen to be in the SERVICE
portion of the menu.
• CONTROL TEST
• EQUIPMENT CONFIGURATION
• VFD CONFIG DATA
• EQUIPMENT SERVICE
• TIME AND DATE
• ICVC CONFIGURATION (PASSWORD)
PASSWORD — When accessing the SERVICE tables, a password must be entered. All ICVC are initially set for a password
of 1-1-1-1.
INPUT TIME AND DATE — Access the TIME AND DATE
table on the SERVICE menu. Input the present time of day,
date, and day of the week. The HOLIDAY parameter should
only be configured to YES if the present day is a holiday.
NOTE: Because a schedule is integral to the chiller control
sequence, the chiller will not start until the time and date have
been set.
CHANGE ICVC CONFIGURATION IF NECESSARY —
From the SERVICE table, access the ICVC CONFIGURATION screen. From there, view or modify the ICVC CCN
address, change to US Imperial (English) or Metric (SI) units,
LID Language, and change the password. If there is more than
one chiller at the jobsite, change the ICVC CCN address on
each chiller so that each chiller has its own address. Note and
record the new address. Change the screen to Metric (SI) units
as required, and change the ICVC password if desired.
2. Use the ENTER softkey to scroll to US imp or
METRIC.
3. Press the softkey that corresponds to the units desired for
display on the ICVC (e.g., US imp or METRIC).
MODIFY CONTROLLER IDENTIFICATION IF NECESSARY — The ICVC module address can be changed from the
ICVC CONFIGURATION screen. Change this address for
each chiller if there is more than one chiller at the jobsite. Write
the new address on the ICVC module for future reference.
INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY — The EQUIPMENT SERVICE table has six
service tables:
1. OPTIONS
2. SETUP1
3. SETUP2
4. LEADLAG
5. RAMP_DEM
6. TEMP_CTL
Check VFD_CONFIG TABLE — Enter the VFD_CONF
screen on the ICVC by entering the following screen
sequence:
• MENU
• SERVICE
• Password (default 1111)
• VFD CONFIG DATA
• Password (default 4444)
• VFD_CONF
59
Confirm that the following parameters in the VFD_CONF
screen match the values on the Machine Electrical Data Nameplate (see Fig. 37):
• Motor Nameplate Voltage — Voltage required to run at
motor rating.
• Compressor 100% Speed — Compressor speed required to
run at chiller design point.
• Rated Line Voltage — Nominal line voltage selected for the
job site.
• Rated Line Amps — Line current required for the chiller to
run at the design point.
• Rated Line Kilowatts — Line power required for the chiller
to run at the design point.
• Motor Rated Load kW — Power consumed by the motor
when running at the chiller design point.
• Motor Rated Load Amps — Motor current required for the
chiller to run at the design point.
• Motor Nameplate Amps — Motor nameplate full load
amps.
• Motor Nameplate RPM — Rated speed of the motor
when running at motor nameplate rated frequency, rated
current, and rated voltage.
• Motor Nameplate kW — Motor nameplate rated power.
• Inverter PWM Frequency — Sets the carrier frequency
for the pulse width modulation output.
NOTE: Other parameters on these screens are normally left at
the default settings; however, they may be changed by the
operator as required. The voltage and current imbalance level
and imbalance persistence time on the VFD_CONF table can
be adjusted to increase or decrease the sensitivity of these fault
conditions. Increasing time or persistence decreases sensitivity.
Decreasing time or persistence increases sensitivity to the fault
condition.
Modify Minimum and Maximum Load Points (HGBP
DELTA T1/ HGBP DELTA P1, HGBP DELTA T2/ HGBP
DELTA P2) If Necessary — The default settings of the stall
prevention parameters in the OPTIONS screen are set so the
optional HGBP will not be energized during normal operating
conditions. In addition to stall prevention, hot gas bypass may
be useful for preventing excessive recycle restarts and maintaining temperature control in response to rapid load changes at
low compressor speed. The chiller needs only to close the
optional hot gas bypass valve to increase capacity when the
chiller is running at low load with hot gas bypass active. It
takes a few minutes for the chiller to start if it has shut down in
recycle restart mode.
When HGBP option is set to 1, hot gas bypass operation can
be adjusted for minimum chiller load and lift control. The
HGBP DELTA T1/HGBP DELTA P1, HGBP DELTA T2/
HGBP DELTA P2 parameters in the OPTIONS screen determine when the optional hot gas bypass valve will open and
close. These points should be set based on individual chiller
operating conditions.
An example of such a configuration is shown below.
Refrigerant: HCFC-134a
Estimated Minimum Load Conditions:
44 F (6.7 C) LCL
45.5 F (7.5 C) ECL
43 F (6.1 C) Suction Temperature
70 F (21.1 C) Condensing Temperature
Estimated Maximum Load Conditions:
44 F (6.7 C) LCL
54 F (12.2 C) ECL
42 F (5.6 C) Suction Temperature
98 F (36.7 C) Condensing Temperature
Calculate Maximum Load — To calculate the minimum load
points, use data from the sales requisition or estimate the
chilled liquid delta T based on a percentage of full load where
the HGBP should be energized. The minimum condensing
pressure can be based on the entering condenser liquid temperature available at minimum load. Use the proper saturated pressure and temperature for R-134a.
Suction Temperature:
43 F (6.1 C) = 38 psig (262 kPa) saturated
refrigerant pressure (R-134a)
Condensing Temperature:
70 F (21.1 C) = 71 psig (490 kPa) saturated
refrigerant pressure (R-134a)
Minimum Load HGBP DELTA T1 (at 15% load):
0.15 X (54-44) = 1.5º F (0.15 X (12.2 – 6.7) = 0.8º C
Minimum Load HGBP DELTA P1:
71 – 38 = 33 psid (490 – 262 = 228 kPad)
Determine HGBP DELTA T2/HGBP DELTA P1:
Set HGBP DELTA T2 equal to 0.1º F larger than HGBP
DELTA T1:
HGBP DELTA T2 = HGBP DELTA T1 + 0.1 = 1.6º F
(0.8 + 0.06 = 0.9º C)
Set HGBP DELTA P2 to a large value to create a steep slope
(see Fig. 22 and 23) HGBP DELTA P2 = 200 psid (1379 kPa).
If the hot gas bypass is energized too soon or too late:
HGBP ENERGIZED
TOO SOON
Decrease HGBP DELTA T1
and HGBP DELTA T2 by
0.5° F (0.3° C)
HGBP ENERGIZED
TOO LATE
Increase HGBP DETLA T1
and HGBP DELTA T2 by
0.5° F (0.3° C)
If variable evaporator flow is applied, changes to
DELTA T1 proportional to the reduction in evaporator liquid
flow rate are required.
The differential pressure (ΔP) and temperature (ΔT) can be
monitored during chiller operation by viewing ACTIVE
DELTA P and ACTIVE DELTA T (HEAT_EX screen). Comparing HGBP DELTA T to ACTIVE DELTA T will determine
when the HGBP valve will open. The smaller the difference
between the HGBP DELTA T and the ACTIVE DELTA T
values, the closer to stall prevention or the point at which the
HGBP will open.
If the ACTIVE DELTA T is less than the HGBP DELTA T,
the HGBP valve will be activated. The HGBP will be deactivated once the ACTIVE DELTA T is greater than the HGBP
DELTA T plus the HGBP DEADBAND if the ACTIVE DELTA
P is less than HGBP DELTA P1.
When the HGBP option is set to 2, HGBP on DELTA T
should be based on the estimated minimum load conditions as
was HGBP DELTA T1 in the example above. HGBP OFF
DELTA T functions similar to a deadband above the temperature entered in HGBP ON DELTA T as shown in Fig. 23.
MODIFY EQUIPMENT CONFIGURATION IF NECESSARY — The EQUIPMENT SERVICE table has screens to
select, view, or modify parameters. Carrier’s certified drawings
have the configuration values required for the jobsite. Modify
these values only if requested.
SERVICE Screen Modifications — Change the values on
these screens according to specific job data. See the certified
drawings for the correct values. Modifications can include:
• Chilled liquid reset
• Entering chilled liquid control (Enable/Disable)
• 4 to 20 mA demand limit
• Auto restart option (Enable/Disable)
• Remote contact option (Enable/Disable)
Owner-Modified CCN Tables — The following EQUIPMENT CONFIGURATION screens are described for reference
only.
60
OCCDEFCS — The OCCDEFCS screen contains the Local
and CCN time schedules, which can be modified here or on the
SCHEDULE screen as described previously.
HOLIDAYS — From the HOLIDAYS screen, the days of the
year that holidays are in effect can be configured. See the
holiday paragraphs in the Controls section for more details.
BRODEF — The BRODEF screen defines the start and end of
daylight savings time. By default this feature is enabled. Enter
the dates for the start and end of daylight savings if required
for your location. Note that for DAY OF WEEK, 1 represents
Monday. START WEEK and STOP WEEK refer to the instance
of the selected DAY OF WEEK during the selected START
MONTH and year. To disable the feature, change START
ADVANCE and STOP BACK times to 0 (minutes). In the
BRODEF table the user may also identify a chiller as the time
broadcaster for a CCN network with TIME BROADCAST
ENABLE. There should be only one device on a CCN network
which is designated as the time broadcaster.
ALARM ROUTING (Fig. 38) — ALARM ROUTING is in
the table SERVICE/EQUIPMENT CONFIGURATION/
NET_OPT under the heading Alarm Configuration. ALARM
ROUTING consists of an 8-bit binary number. Only bits 1, 2,
and 4 (counting from the left) are used. The bits can be set by
any device which can access and change configuration tables.
If any of these 3 bits is set to 1, the ICVC will broadcast any
alarms which occur.
Bit 1: Indicates that the alarm should be read and processed by
a front end device, such as a ComfortWORKS® device.
a TeLINK or Autodial Gateway module.
an alarm printer interface (an optional module), ServiceLink,
or a DataLINK™ device.
The RE-ALARM TIME is a time period after which, if a
preexisting and previously broadcast alarm has not been
cleared, it will be rebroadcast on the CCN network.
Other Tables — The CONSUME, NET_OPT, and RUNTIME screens contain parameters used with a CCN system.
See the applicable CCN manual for more information on these
screens. These tables can only be defined from a CCN
Building Supervisor.
Perform a Control Test — Check the safety controls
status by performing an automated control test. Access the
CONTROL TEST table and select a test to be performed function (see Tables 11 and 12).
The Automated Control Test checks all outputs and inputs
for function. The compressor must be in the OFF mode to
operate the controls test. The compressor can be put in OFF
mode by pressing the STOP push-button on the ICVC. Each
test asks the operator to confirm the operation is occurring and
whether or not to continue. If an error occurs, the operator can
try to address the problem as the test is being done or note the
problem and proceed to the next test.
When the control test is finished or the EXIT softkey is
pressed, the test stops, and the CONTROL TEST menu displays. If a specific automated test procedure is not completed,
access the particular control test to test the function when
ready. The CONTROL TEST menu is described in Table 11.
Table 11 — Control Tests
CCM Thermistors Check of all thermistors.
CCM Pressure
Check of all transducers.
Transducers
Checks operation of pump outputs; pumps are activated.
Pumps
Also tests associated inputs such as flow or pressure.
Discrete Outputs Activation of all on/off outputs individually.
Oil Reclaim
Checks CCM 4-20mA oil reclaim output with
Output
power removed from oil reclaim actuator.
Head Pressure
Manually varies the head pressure output
Output
from low voltage field wiring terminal strip.
Pumpdown prevents the low refrigerant alarm during
Pumpdown/
evacuation so refrigerant can be removed form the unit.
Lockout
Also locks the compressor off and starts the liquid
pumps.
Terminate
To charge refrigerant and enable the chiller
Lockout
to run after pumpdown lockout.
NOTE: During any of the tests, an out-of-range reading will have an asterisk
(*) next to the reading and a message will be displayed.
The EVAPORATOR PRESSURE, CONDENSER PRESSURE, DISCHARGE PRESSURE, and OIL PRESSURE
DELTA P pressure transducers should be calibrated prior to
start-up. If pressure transducers are installed on the waterbox
nozzles, CHILLED LIQUID DELTA P and CONDENSER
LIQUID DELTA P transducers should also be calibrated.
Pressure Transducer and Optional Flow
Device Calibration — Transducers measuring single
ALARM CONTROL
ALARM ROUTING
pressure values (such as CONDENSER PRESSURE and
EVAPORATOR PRESSURE) are calibrated individually, while
a pair of transducers measuring a pressure differential (OIL
PRESSURE DELTA P, CHILLED LIQUID DELTA P, or
CONDENSER LIQUID DELTA P) are calibrated together as a
differential. Transducers for sensing liquid side flow are not
provided as standard. Oil pressure, refrigerant pressure and
liquid delta P readings can be viewed and calibrated from the
COMPRESS and HEAT_EX screens on the ICVC controller.
Each transducer or transducer pair can be calibrated at two
points: “zero” (0 psig or 0 kPa) and “high end” (between 25
and 250 psig, or between 173 and 1724 kPa). It is good practice to calibrate at initial start-up. Calibration is particularly
important at high altitudes to ensure the proper refrigerant
temperature-pressure relationship.
ZERO POINT CALIBRATION — Shut down the compressor, and cooler and condenser pumps. There must be no water
flow through the heat exchangers, but these systems must be
filled. For differential pairs, leave the transducers installed. For
single value transducers, disconnect the transducer’s electrical
cable, remove the sensor from its Schrader fitting, then reconnect the cable.
NOTE: If the cooler or condenser vessels are at 0 psig (0 kPa)
or are open to atmospheric pressure, the transducers can be
calibrated for the zero point without removal.
Alarm routing settings should be left at default settings and only be
changed by technicians trained in CCN. These settings determine
which CCN system elements will receive and process alarms sent
by the ICVC. Input for the decision consists of eight digits, each of
which can be set to either 0 or 1. Setting a digit to 1 specifies that
alarms will be sent to the system element that corresponds to that
digit. Setting all digits to 0 disables alarm processing. Digits in
this decision correspond to CCN system elements in the following
manner:
Alarm Printer Interface Module
Autodail Gateway
Local Building Supervisors(s)
or ComfortWORKS
1
1
0
1
0
0
a23-1627
0
0
unused
NOTE: If your CCN does not contain ComfortWORKS® controls or
a Building Supervisor, Autodial Gateway, or APIM to serve as an
alarm acknowledger, set all digits in this decision to 0 in order to
prevent unnecessary activity on the CCN Communication Bus.
Allowable Entries
00000000 to 11111111
0 = Disabled, 1 = Enabled
Default Value
10000000
Fig. 38 — Alarm Control and Alarm Routing
61
Access the HEAT_EX or COMPRESS screen under the
STATUS menu, and view the particular transducer reading
(OIL PRESSURE DELTA P is in the COMPRESS screen; all
others are in the HEAT_EX screen). If the displayed reading is
not 0 psi (0 kPa), press the SELECT key to highlight the
associated line in the display, then the ENTER key. (For zero
point calibration, the INCREASE and DECREASE keys have
no effect.) The value should change to 0.0.
If the ICVC fails to accept the zero point calibration, the
value will not change to 0.0 and the display will show “Higher
Force In Effect”. This indicates that the sensor voltage is out of
the acceptable range. For each single value transducer there are
3 terminals at the CCM: 0 vdc (low) connected to the black
wire, “sensor” voltage connected to the white or clear wire, and
5.00 vdc (high) connected to the red wire. With a base supply
voltage of 5.00 volts, the acceptable range of voltage taken
between the low (black wire) and sensor terminals (white or
clear wire) for zero point calibration is 0.40 to 0.55 v. For each
transducer differential pair there are two 3-terminal sets at the
CCM. With a base supply voltage of 5.00 volts, the acceptable
range of voltage taken between the sensor terminal (white or
clear wire) for the higher pressure transducer (liquid inlet or oil
pump discharge) and the sensor terminal (white or clear wire)
for the lower pressure transducer (liquid outlet or oil sump) for
zero point calibration is -0.065 to +0.085 v. If this occurs with a
differential pair, one possible remedy is to swap the high end
(e.g., inlet) and low end (e.g., outlet) transducers. In most cases
this puts the voltage difference of the sensor pair within the
acceptable range.
HIGH END CALIBRATION — High end calibration can be
performed between 25 and 250 psig (173 and 1724 kPa),
comparing the pressure readings in the ICVC display to an
accurate refrigeration gage. High end calibration may improve
transducer accuracy over the full pressure range. High end
calibration is not recommended for transducer differential
pairs. Pressure can be provided by attaching a regulated
250 psig (1724 kPa) pressure source, such as from a nitrogen
cylinder, to the transducer. It is good practice to perform the
high end calibration near a pressure that the sensor will
typically be exposed to.
Access the HEAT_EX screen under the STATUS menu, and
the CONDENSER PRESSURE or EVAPORATOR PRESSURE
to the reference pressure gage. To change the displayed reading, press the SELECT key to highlight the associated line in
the display, then the INCREASE or DECREASE key to set the
new value, then the ENTER key. Generally, the value can be
changed to any value within ±15% of a nominal value.
NOTE: Prior calibrations may have shifted the present precalibration value from the center of this range. In this case, the
limit of acceptable new values will be less than 15% in one
direction.
If the ICVC fails to accept the high end calibration, the
value will not change and the display will show “Higher Force
In Effect”. This indicates that the sensor voltage is out of the
acceptable range for the entered value. In this case, the
pressure transducer may need to be replaced.
Each pressure transducer is supplied with 5 vdc power from
the CCM through the red wire. Pressure transducer readings
are derived from voltage ratio, not absolute voltage, which
compensates for any reference voltage variation. If this power
supply fails, a transducer voltage reference alarm (239) is
generated. If transducer readings are suspected of being faulty,
check the supply voltage, measured between the high and low
(red wire and black wire) terminals of any transducer 3 terminal connection at the CCM. This is also displayed in CONTROL TEST under PRESSURE TRANSDUCERS.
Check Optional Pumpout System Controls
and Compressor — Controls include an on/off switch, a
0.5-amp fuse for the secondary side of the transformer,
0.25 amp fuses for the primary side of the transformer, the
compressor overloads, an internal thermostat, a compressor
contactor, refrigerant low pressure cut-out and a refrigerant
high pressure cutout. The high pressure cutout is factory set to
open at 185 psig (1276 kPa) and reset at 140 psig (965 kPa).
The low pressure cutout is factory set to open at 7 psia (–15.7
in. HG) and close at 9 psia (–11.6 in. HG). Ensure the watercooled condenser has been connected. Ensure oil is visible in
the compressor sight glass. Add oil if necessary.
See the Pumpout and Refrigerant Transfer Procedures and
Optional Pumpout System Maintenance sections, pages 69 and
78, for details on the transfer of refrigerant, oil specifications,
etc.
High Altitude Locations — Because the chiller is initially calibrated at sea level, it is necessary to recalibrate the
pressure transducers if the chiller has been moved to a high
altitude location. See the calibration procedure in the Troubleshooting Guide section.
Table 12 — Control Test Menu Functions
TESTS TO BE
PERFORMED
1. Thermistors
2. Pressure
Transducers
3. Pumps
4. Discrete Outputs
5. Oil Reclaim Output
6. Head Pressure
Output
7. Pumpdown
Lockout
8. Terminate Lockout
62
DEVICES TESTED
Leaving Cond Liquid
Comp Discharge Temp
Oil Sump Temp
Vaporizer Temp
Spare Temperature 1
Spare Temperature 2
Remote Reset Sensor
Evaporator Pressure
Condenser Pressure
Discharge Pressure
Chilled Liquid Delta P
Condenser Liquid Delta P
Transducer Voltage Ref
Relative Humidity
Operates Pump, Displays Delta P and confirms
flow for oil pump, chilled liquid pump and
condenser liquid pump.
Oil Heater Relay
Vaporizer Heater
Tower Fan Relay Low
Tower Fan Relay High
Alarm Relay
VFD Coolant Solenoid
Shunt Trip Relay
Percentage and mA (% and mA)
Head Pressure Reference (4-20mA)
(The output is 2 mA when the chiller is not
running.)
When using pumpdown/lockout, observe freeze up
precautions when removing charge:
Instructs operator which valves to close and when.
Starts chilled liquid and condenser liquid pumps
and requests flow confirmation.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
pumpout procedures
Turns pumps off after pumpdown.
Locks out compressor.
Starts pumps and monitors flows.
Instructs operator which valves to open and when.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
charging process
Terminates compressor lockout.
• Oil Pump Isolation Valve
• Oil Pressure Regulator Valve
Refer to Fig. 2 and 8 for isolation valve locations.
Charge Refrigerant into Chiller
The transfer, addition, or removal of refrigerant in spring
isolated chillers may place severe stress on external piping
if springs have not been blocked in both up and down
directions. Failure to block springs in both up and down
directions could result in severe personal injury and equipment damage.
Whenever turning the discharge isolation valve, be sure that
the spring-loaded lever lock fully engages within one of the
latch plate detents. This will prevent the valve from opening
or closing during service work or during chiller operation.
CHILLER EQUALIZATION WITH PUMPOUT UNIT —
The following steps describe how to equalize refrigerant pressure on an isolated 23XRV chiller using the pumpout unit.
NOTE: The top valve tee on a unit mounted pumpout is
connected to the condenser and the bottom valve tee is connected to the cooler. This is different from unit mounted
installations on other Carrier chillers.
1. Access the TERMINATE LOCKOUT function on the
CONTROL TEST screen.
2.
IMPORTANT: Turn on the chilled liquid and
condenser liquid pumps to prevent possible freezing.
Always operate the condenser and chilled liquid pumps
during charging operations to prevent freeze-ups. Damage
may result to equipment if the condenser and chilled water
pumps are not operated during pumpdown or charging.
The standard 23XRV chiller is shipped with the refrigerant
already charged in the vessels. However, the 23XRV may be
ordered with a nitrogen holding charge of 15 psig (103 kPa). In
this case, evacuate the nitrogen from the entire chiller, and
charge the chiller from refrigerant cylinders.
Chillers shipped with a factory charge should arrive with all
isolation valves in the open position. Figures 2, 43, 44 and 45
show the location of the isolation valves listed in the Initial
Start-Up Checklist.
CHILLER EQUALIZATION WITHOUT A PUMPOUT
UNIT
3. Refer to Fig. 33. Open valve 4 on the pumpout unit
and open valves 1a and 1b on the chiller cooler and
condenser, Fig. 30-33. Slowly open valve 2 on the
pumpout unit to equalize the pressure. This process
takes approximately 15 minutes.
4. Once the pressures have equalized, the following isolation valves should be opened:
• Discharge Isolation Valve
• Cooler Inlet Valve
• Hot Gas Bypass Valve
• Vaporizer Condenser Gas Valve
• Oil Pump Valve
• Oil Filter Valve
• Oil Pressure Regulator Valve
• Filter/Drier Valve (2 places)
• VFD Cooling Inlet Valve
• VFD Cooling Drain Valve
Refer to pages 5, 6, 11 and 75 for isolation valve locations.
When equalizing refrigerant pressure on the 23XRV chiller
after service work or during the initial chiller start-up, do
not use the discharge isolation valve to equalize. Either the
motor cooling isolation valve or the charging hose (connected between the pumpout valves on top of the cooler
and condenser) should be used as the equalization valve.
To equalize the pressure differential on a refrigerant isolated
23XRV chiller, use the TERMINATE LOCKOUT function of
the CONTROL TEST on the SERVICE menu. This helps to
turn on pumps and advises the operator on proper procedures.
The following steps describe how to equalize refrigerant
pressure in an isolated 23XRV chiller without a pumpout unit.
1. Access TERMINATE LOCKOUT function on the CONTROL TEST screen.
2. IMPORTANT: Turn on the chilled liquid and condenser liquid pumps to prevent freezing.
Whenever turning the discharge isolation valve, be sure
that the spring-loaded lever lock fully engages within one
of the latch plate detents. This will prevent the valve from
opening or closing during service work or during chiller
operation.
The full refrigerant charge on the 23XRV will vary with
chiller components and design conditions, as indicated on the
job data specifications. An approximate charge may be determined by adding the condenser charge to the cooler charge as
listed in Table 13.
3. Slowly open the motor cooling isolation valve. The chiller cooler and condenser pressures will gradually equalize.
This process takes approximately 15 minutes.
4. Once the pressures have equalized, the following isolation valves should be opened:
• Discharge Isolation Valve
• Cooler Inlet Valve
• HGBP Isolation Valve (optional)
• Vaporizer Condenser Gas Valve
• Filter/Drier Isolation Valve (2 places)
• VFD Cooling Isolation Valves (2 places)
• Oil Filter Isolation Valve
Always operate the condenser and chilled liquid pumps
whenever charging, transferring, or removing refrigerant
from the chiller.
63
Table 13 — Refrigerant Charges
FRAME SIZE
COOLER
LENGTH
ft (m)
12
(3.6)
3
14
(4.3)
12
(3.6)
4
14
(4.3)
12
(3.6)
5
14
(4.3)
COOLER
CODE
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
55
56
57
CHARGE AMOUNT (R-134a)
WITH ECONOMIZER
WITHOUT ECONOMIZER
lb (± 25 lb)
kg (± 11 kg)
lb (± 25 lb)
kg (± 11 kg)
800
363
650
295
800
363
650
295
800
363
650
295
910
413
760
345
910
413
760
345
910
413
760
345
900
408
750
340
900
408
750
340
900
408
750
340
1015
460
865
392
1015
460
865
392
1015
460
865
392
1250
567
1100
499
1250
567
1100
499
1250
567
1100
499
1430
649
1280
581
1430
649
1280
581
1430
649
1280
581
The preferred location at which refrigerant should be added
directly into the chiller is through the service valves on top of
the cooler condenser. if these valves are not accessible due to
presence of an attached pumpdown unit which does not have a
storage tank, slowly add charge through the valve connected to
the side of the condenser drain float sump. Adding charge
through the cooler refrigerant pumpout valve at the base of the
cooler (off the liquid line) may force debris into the condenser
float valve and is not recommended.
CHILLER SHIPPED WITH HOLDING CHARGE — Use the
CONTROL TEST TERMINATE LOCKOUT function to
monitor conditions and start the pumps.
If the chiller has been shipped with a holding charge, the
refrigerant is added through the refrigerant charging valve
(Fig. 30-33, valves 1a and 1b) or to the pumpout charging connection. First evacuate the nitrogen holding charge from the
chiller vessels. Charge the refrigerant as a gas until the system
pressure exceeds 35 psig (141 kPa) for HFC-134a. After the
chiller is beyond this pressure the refrigerant should be charged
as a liquid until all the recommended refrigerant charge has
been added.
TRIMMING REFRIGERANT CHARGE — The 23XRV is
shipped with the correct charge for the design duty of
the chiller. The LTD (Leaving Temperature Difference) between the EVAP REFRIG LIQUID TEMP and LEAVING
CHILLED LIQUID can be checked against the design conditions to confirm that the charge is correct. In the case where
leaks have been found and corrected and the LTD is greater
than about 4° F (2.2° C) above design, add refrigerant until the
full load design LTD is approached. (A high cooler LTD can
also be caused by dirty tubes, water box division plate bypass,
a partially closed liquid isolation valve, or the float valve.)
Trimming the charge can best be accomplished when the
design load is available. The calibration of the EVAP REFRIG
LIQUID TEMP and LEAVING CHILLED LIQUID temperature sensors should be confirmed prior to checking for proper
cooler LTD. Compare the difference between EVAP REFRIG
LIQUID TEMP and LEAVING CHILLED LIQUID temperatures to the chiller design conditions. Add or remove refrigerant, if necessary, to bring the cooler leaving temperature
difference to design conditions or within minimum differential.
Check for low load oil recovery after making adjustments to
the refrigerant charge. The bubbling mixture of refrigerant and
oil mixture should be visible through the vaporizer sight glass
at low load when the oil reclaim valve is open. If a bubbling
mixture is not observed when the oil reclaim valve is open, add
refrigerant.
INITIAL START-UP
In order for the Reliance VFD to be eligible for the full
warranty period, the following conditions must be met:
1. The chiller must be started by a technician that has completed Reliance LiquiFlo2 training.
2. The start-up technician must be registered with Reliance.
3. The start-up technician must register the chiller start-up
on the Reliance web site.
Preparation — Before starting the chiller, verify:
1. Power is on to the CB2 control power circuit breaker, oil
pump relay, tower fan starter, oil heater relay, and the
chiller control center.
2. The CB1 main control center circuit breaker is in the On
position.
3. Cooling tower liquid is at proper level and at-or-below
design entering temperature. Check cooling tower bypass
valve.
4. Chiller is charged with refrigerant and all refrigerant and
oil valves are in their proper operating positions.
5. Oil is at the proper level in the oil sump sight glass.
6. The Oil Sump Temperature must be above 140 F (60 C)
or CALC EVAP SAT TEMP plus 15º F (8.3º C) before
the controls will allow the chiller to start to ensure that
a sufficient amount of refrigerant has been driven out of
the oil.
7. All valves listed on page CL-2 of the Initial Start-Up
Checklist are fully open.
8. The VFD cold plate refrigerant isolation valves are open.
64
To start the chiller the STOP override setting must first be
removed. Access the MAINSTAT screen and using NEXT
or PREVIOUS softkeys highlight CHILLER START/STOP.
The 3 softkeys that appear represent 3 choices:
SHIPPING
BRACKET
•
•
•
START — forces the chiller ON
STOP — forces the chiller OFF
RELEASE — puts the chiller under remote or schedule
control.
To return the chiller to normal control, press the
RELEASE softkey followed by the ENTER softkey. For
more information, see Local Start-Up, page 46.
The default ICVC screen message line indicates which
command is in effect.
Check Chiller Operating Condition — Check to
be sure that chiller temperatures, pressures, liquid flows, and
oil and refrigerant levels indicate the system is functioning
properly.
Instruct the Customer Operator — Ensure the operator(s) understands all operating and maintenance
procedures. Point out the various chiller parts and explain their
function as part of the complete system.
COOLER-CONDENSER — Float chamber, relief valves,
refrigerant charging valve, temperature sensor locations,
pressure transducer locations, Schrader fittings, waterboxes
and tubes, and vents and drains.
OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM — Transfer valves and pumpout system,
refrigerant charging and pumpdown procedure, and relief
devices.
COMPRESSOR ASSEMBLY — Motor cooling system, oil
system, temperature and pressure sensors, sight glasses,
motor temperature sensors, synthetic oil, and compressor
serviceability.
COMPRESSOR LUBRICATION SYSTEM — Concentrator, oil pump, oil filter, oil heaters, oil charge and specification,
strainers, sight glasses, operating and shutdown oil level, temperature and pressure sensors, and oil charging connections.
CONTROL SYSTEM — CCN and LOCAL start, reset,
menu, softkey functions, ICVC operation, occupancy schedule,
set points, safety controls, and auxiliary and optional controls.
AUXILIARY EQUIPMENT — Disconnects, separate electrical sources, pumps, cooling tower, chilled liquid strainers,
and condenser liquid strainers.
DESCRIBE CHILLER CYCLES — Refrigerant, motor
cooling, lubrication, and oil reclaim.
REVIEW MAINTENANCE — Scheduled, routine, and
extended shutdowns, importance of a log sheet, importance of
liquid treatment and tube cleaning, and importance of maintaining a leak-free chiller.
SAFETY DEVICES AND PROCEDURES — Electrical disconnects, relief device inspection, and handling refrigerant.
CHECK OPERATOR KNOWLEDGE — Start, stop, and
shutdown procedures, safety and operating controls, refrigerant
and oil charging, and job safety.
REVIEW THE START-UP, OPERATION AND MAINTENANCE MANUAL
a23-1565
Fig. 39 — Control Center Shipping Brace
9. Remove the control center shipping brace (see Fig. 39).
Operating the chiller with the shipping brace attached may
result in excessive vibration and noise. The shipping brace
should be removed to avoid possible equipment damage.
Do not permit liquid or brine that is warmer than 110 F
(43 C) to flow through the cooler or condenser. Refrigerant
overpressure may discharge through the relief valves and
result in the loss of refrigerant charge.
10. Access the CONTROL TEST screen. Scroll down on the
TERMINATE LOCKOUT option. Press the SELECT (to
enable the chiller to start) and answer YES to restore unit
to operating mode. The chiller is locked out at the factory
in order to prevent accidental start-up.
Check Oil Pressure and Compressor Stop —
Start the chiller and allow it to automatically ramp load.
1. Two minutes after start-up, note the OIL PRESSURE
DELTA P reading on the ICVC default screen. The OIL
PRESSURE DELTA P is the difference between the oil
pressure leaving the oil filter and the oil sump pressure.
The minimum OIL PRESSURE DELTA P is 18 psid
(124 kPad) after OIL PRESSURE VERIFY TIME is exceeded. The OIL PRESSURE DELTA P is displayed on
the COMPRESS, STARTUP, PRESSURE TRANSDUCERS, PUMPS, and DEFAULT screens. A normal full load
reading is approximately 20 to 28 psid (138 to 193 kPad).
2. Press the STOP softkey and listen for any unusual sounds
from the compressor as it coasts to a stop.
To Prevent Accidental Start-Up — The chiller is
shipped with the CHILLER START/STOP parameter in the
MAINSTAT screen set to STOP. Once installed, a chiller STOP
override setting may be entered to prevent accidental start-up
during service or whenever necessary. Access the MAINSTAT
screen and using the NEXT or PREVIOUS softkeys, highlight the CHILLER START/STOP parameter. Override the current START value by pressing the SELECT softkey. Press the
STOP softkey followed by the ENTER softkey. The word
SUPVSR! displays on the ICVC indicating the STOP override
is in place.
Manuals and notebooks should not be stored under the
VFD power module, they will block air flow into the
power module cooling fan and cause the VFD to overheat.
65
5. The condenser pressure and temperature varies with the
chiller design conditions. Typically the pressure will
range between 60 to 135 psig (329 to 780 kPa) with a corresponding temperature range of 60 to 105 F (15 to 41 C).
The condenser entering liquid temperature may be
controlled below the specified design entering liquid
temperature to save on compressor kilowatt requirements
but, not be below 55 F (12.8 C).
6. Cooler pressure and temperature also will vary with the
design conditions. Typical pressure range will be between
30 to 40 psig (204 to 260 kPa) with temperature ranging
between 34 and 45 F (1 and 8 C).
7. The compressor may operate at full capacity for a short
time after the pulldown ramping has ended, even though
the building load is small. The active electrical demand
setting can be overridden to limit the compressor kW, or
the pulldown rate can be decreased to avoid a high
demand charge for the short period of high demand operation. Pulldown rate can be based on load rate or temperature rate by PULLDOWN RAMP TYPE in the
RAMP_DEM screen. AMPS or KW RAMP%/MIN is accessed on the Equipment SERVICE screen, RAMP_DEM
table (Table 3, Example 22). TEMP PULLDOWN
RAMP/MIN is accessed on the TEMP_CTL screen.
OPERATING INSTRUCTIONS
Operator Duties
1. Become familiar with the chiller and related equipment
before operating the chiller.
2. Prepare the system for start-up, start and stop the chiller,
and place the system in a shutdown condition.
3. Maintain a log of operating conditions and document any
abnormal readings.
4. Inspect the equipment, make routine adjustments, and
perform a Control Test. Maintain the proper oil and
refrigerant levels.
5. Protect the system from damage during shutdown
periods.
6. Maintain the set point, time schedules, and other PIC III
functions.
Prepare the Chiller for Start-Up — Follow the steps
described in the Initial Start-Up section, page 64.
To Start the Chiller
1. Start the liquid pumps, if they are not automatic.
2. On the ICVC default screen, press the LOCAL or
CCN softkey to start the system. If the chiller is in the
OCCUPIED mode and the start timers have expired, the
start sequence will start. Follow the procedure described
in the Start-Up/Shutdown/Recycle Sequence section,
page 46.
To Stop the Chiller
1. The occupancy schedule starts and stops the chiller automatically once the time schedule is configured.
2. The STOP button must be pressed for one second before
the alarm light blinks once to confirm the button has been
pressed. The compressor will then follow the normal
shutdown sequence as described in the Controls section.
The chiller will not restart until the CCN or LOCAL
softkey is pressed. The chiller is now in the OFF control
mode.
Check the Running System — After the compres-
sor starts, the operator should monitor the ICVC display and
observe the parameters for normal operating conditions:
1. The oil sump temperature will vary from 50 deg F to
140 deg F (10 deg C to 60 deg C) depending on the operating conditions. If the chiller has not been running for a
few hours the OIL SUMP TEMP will be warmer than the
CALC EVAP SAT TEMP. When the chiller is not running, the oil heater is energized whenever the OIL SUMP
TEMP is less than the smaller of 140 (60 deg C) or
53 deg F (29.4 deg C) greater than the CALC EVAP SAT
TEMP. The OIL SUMP TEMP generally decreases slowly following start-up and eventually stabilizes at a point
lower than the temperature maintained during shut down.
The OIL PRESS DELTA P increases above 18 psid
(124 kPad) during start-up and generally does not vary by
more than ± 2 psid (14 kPad). The level in the oil sump is
generally very stable. Changes in the oil level occur very
slowly.
2. When the compressor is running, the liquid level should
be visible in the oil sump or the strainer housing sight
glass. Low oil pressure alarms are imminent if the oil level drops below the bottom of the oil strainer housing sight
glass.
3. The OIL PRESSURE DELTA P displayed on the ICVC
default screen is equal to the difference between the oil
pressure leaving the oil filter and the oil sump pressure
transducer readings. Typically the reading will be
between 20 and 28 psid (138 to 193 kPad) after the oil
pressure ramp up is complete.
4. The moisture indicator (dry-eye) sight glass on the refrigerant motor cooling line should indicate refrigerant flow
and a dry condition.
FAILURE TO STOP — If the alarm light does not blink after
pressing and holding the stop button for at least one second and
the chiller fails to stop, the operator should open the main
circuit breaker on the front of the control panel.
IMPORTANT: Do not attempt to stop the chiller by
opening an isolating knife switch. High intensity arcing
may occur.
Do not restart the chiller until the problem is diagnosed and
corrected.
After Limited Shutdown — No special preparations
should be necessary. Follow the regular preliminary checks and
starting procedures.
Preparation for Extended Shutdown — The refrigerant should be transferred into the pumpout storage tank (if
supplied; see Pumpout and Refrigerant Transfer Procedures) to
reduce chiller pressure and the possibility of leaks. Maintain a
holding charge of 5 to 10 psi (34 to 69 kPa) of refrigerant or
nitrogen to prevent air from leaking into the chiller.
If freezing temperatures are likely to occur in the chiller
area, drain the chilled liquid, condenser liquid, and the
pumpout condenser liquid circuits to avoid freeze-up. Keep the
waterbox drains open.
Leave the oil charge in the chiller with the oil heater and
controls energized to maintain the minimum oil reservoir
temperature.
66
After Extended Shutdown — Ensure the liquid sys-
Cold Weather Operation — When the entering con-
tem drains are closed. It may be advisable to flush the liquid
circuits to remove any soft rust which may have formed. This
is a good time to brush the tubes and inspect the Schrader
fittings on the optional liquid side flow devices for fouling, if
necessary.
Check the cooler pressure on the ICVC default screen and
compare it to the original holding charge that was left in the
chiller. If (after adjusting for ambient temperature changes) any
loss in pressure is indicated, check for refrigerant leaks. See
Check Chiller Tightness section, page 49.
Recharge the chiller by transferring refrigerant from the
pumpout storage tank (if supplied). Follow the Pumpout and
Refrigerant Transfer Procedures section, page 69. Observe
freeze-up precautions.
Carefully make all regular preliminary and running system
checks. Perform a Control Test before start-up. If the oil level
appears abnormally high, the oil may have absorbed refrigerant. A LOW OIL TEMPERATURE prestart alert will be
declared if the oil temperature is not greater than the CALC
EVAP SAT TEMP plus 15 F (8.3 C) or 140 F (60 C), whichever is lower.
denser liquid drops very low (55 F [13 C] minimum), the operator or tower control should automatically cycle the cooling
tower fans off to keep the temperature up. Piping may also be
arranged to bypass the cooling tower. The PIC III controls have
a Tower Fan Low control contact that can be used to assist in
this control (terminals 5 and 6 on the TB2 hazardous voltage
field wiring terminal strip).
Refrigeration Log — A refrigeration log, such as the
one shown in Fig. 40, provides a convenient checklist for
routine inspection and maintenance, and provides a continuous
record of chiller performance. It is an aid in scheduling routine
maintenance and in diagnosing chiller problems.
Keep a record of the chiller pressures, temperatures, and
liquid levels on a sheet similar to that shown. Automatic
recording of PIC III data is possible through the use of CCN
devices such as the Data Collection module and a Building
Supervisor. Contact your Carrier representative for more
information.
67
68
Press.
Temp
Refrigerant
Liquid
Pressure
In Out GPM
COOLER
Temp
In Out
Press. Temp
Refrigerant
MODEL NO.
Liquid
Pressure
In Out GPM
CONDENSER
COMPRESSOR
Line
kW
OPERVFD
ATOR
Avg.
Rectifier Coolant INITIALS
Load Inverter
Temp
Flow
Current Temp
VFD
REFRIGERANT TYPE
Oil
Oil
Oil
Comp. Avg.
Avg.
Reclaim Reclaim
Oil
Temp
Press Sump Disch.
Line
Line
Delta T Output Level Delta
P
Temp
Temp
Current
Voltage
In Out
CONCENTRATOR
SERIAL NO.
Fig. 40 — Refrigeration Log: Carrier 23XRV Hermetic Screw Refrigeration
REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, operating hours, and start counts. Include amounts.
TIME
DATE:
Plant
REMARKS
counterclockwise to open. Frontseating the valve closes
the refrigerant line and opens the gage port to compressor
pressure.
2. Ensure that the compressor holddown bolts have been
loosened to allow free spring travel.
3. Open the refrigerant inlet valve on the pumpout
compressor.
4. Oil should be visible in the pumpout unit compressor
sight glass under all operating conditions and during
shutdown. If oil is low, add oil as described under
Optional Pumpout System Maintenance section, page 78.
The pumpout unit control wiring schematic is detailed in
Fig. 41.
TO READ REFRIGERANT PRESSURES during pumpout or
leak testing:
1. The ICVC display on the chiller control center is suitable
for determining refrigerant-side pressures and low (soft)
vacuum. To assure the desired range and accuracy when
measuring evacuation and dehydration, use a quality vacuum indicator or manometer. This can be placed on the
Schrader connections on each vessel by removing the
evaporator or condenser pressure transducer (Fig. 3).
2. To determine pumpout storage tank pressure, a 30 in. Hg
vacuum –0-400 psi (–101-0-2769 kPa) compound gage is
attached to the storage tank.
3. Refer to Fig. 31-33, and 41 for valve locations and
numbers.
PUMPOUT AND REFRIGERANT
TRANSFER PROCEDURES
Preparation — The 23XRV chiller may come equipped
with an optional pumpout storage tank, pumpout system, or
pumpout compressor. The refrigerant can be pumped for
service work to either the chiller compressor evaporator vessel
or chiller condenser vessel by using the optional pumpout
system. If a pumpout storage tank is supplied, the refrigerant
can be isolated in the storage tank. The following procedures
describe how to transfer refrigerant from vessel to vessel and
perform chiller evacuations.
Always run the chiller cooler and condenser liquid pumps
and always charge or transfer refrigerant as a gas when the
chiller pressure is less than 35 psig (241 kPa). Below these
pressures, liquid refrigerant flashes into gas, resulting in
extremely low temperatures in the cooler/condenser tubes
and possibly causing tube freeze-up.
During transfer of refrigerant into and out of the optional
storage tank, carefully monitor the storage tank level gage.
Do not fill the tank more than 90% of capacity to allow for
refrigerant expansion. Overfilling may result in damage to
the tank or personal injury.
Transfer, addition, or removal of refrigerant in springisolated chillers may place severe stress on external piping
if springs have not been blocked in both up and down
directions.
Do not mix refrigerants from chillers that use different
compressor oils. Compressor damage can result.
Operating the Optional Pumpout Unit
1. Be sure that the suction and the discharge service valves
on the optional pumpout compressor are open (backseated) during operation. Rotate the valve stem fully
C
2 OL
C
2 OL
C
2 OL
L1
FIELD
POWER
SUPPLY
L2
MTR-1
L3
GND
L1
H4
CONTROL POWER
TRANSFORMER X1
XFMR-1
69 VA
1
X2
X2
55-1
OFF
AUTO ON
2
2
3
C
FU
GND
HTR
MTR
NC
OL
SS
0.5A
FU3
HIGH PRESSURE
SAFETY
NC OPEN > 185psig
2
CRANKCASE HEATER
240-600v
27-40 WATT
7
0.25A
0.25A
FU2
FU1
H1
HTR-1
8
L2
PUMP OUT
COMPRESSOR
LOW PRESSURE CONTROL
NC OPEN < 7 psia (-15.7 in. HG)
CLOSE > 9 psia (-11.6 in. HG)
—
—
—
—
—
—
—
—
LEGEND
Contactor
Fuse
Ground
Heater
Motor
Normally Closed
Overload
Selector Switch
6
4
C
5
X2
a23-1615
Fig. 41 — 23XRV Pumpout Unit Wiring Schematic
69
charging valve 10 to let liquid refrigerant drain into
the chiller.
Chillers with Storage Tanks — In the Valve/Condi-
tion tables that accompany these instructions, the letter “C”
indicates a closed valve. Figures 31-33 and 42 show the
locations of the valves.
VALVE
CONDITION
VALVE
2
VALVE
CONDITION
VALVE
CONDITION
VALVE
3
COMPRESSOR
VALVE
5
a23-1546
LEAVING
WATER
CONDENSER
OIL FILL
FITTING
OIL
SEPARATOR
VALVE
CONDITION
Fig. 42 — Optional Pumpout Unit
During transfer of refrigerant into and out of the 23XRV
storage tank, carefully monitor the storage tank level gage.
Do not fill the tank more than 90% of capacity to allow for
refrigerant expansion. Overfilling may result in damage to
the tank and personal injury.
VALVE
CONDITION
1b
2
C
3
4
C
5
C
6
7
C
10
C
5
6
7
10
11
1a
1b
2
C
3
4
5
C
6
7
10
11
1a
1b
2
3
C
4
C
5
6
7
C
10
C
11
1a
C
1b
C
2
C
3
C
4
C
5
C
6
C
7
C
10
C
11
1a
1b
2
C
3
4
C
5
C
6
7
C
10
C
11
b. Slowly open valve 5 and refrigerant charging
valves 7 and 10 to allow liquid refrigerant to drain
by gravity into the storage tank.
1. Equalize refrigerant pressure.
a. Turn on chiller water pumps and monitor chiller
pressures.
b. Close pumpout and storage tank valves 2, 4, 5, and
10, and close refrigerant charging valve 7; open
chiller isolation valve 11 and any other chiller isolation valves, if present.
c. Open pumpout and storage tank valves 3 and 6;
open chiller valves 1a and 1b.
1a
4
C
l. Turn off pumpout condenser water.
TRANSFER THE REFRIGERANT FROM CHILLER TO
PUMPOUT STORAGE TANK
1. Equalize refrigerant pressure.
a. Valve positions:
TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK TO CHILLER
VALVE
CONDITION
3
h. Turn on pumpout condenser water.
i. Run the pumpout compressor in manual mode until
the storage tank pressure reaches 5 psig (34 kPa),
18 in. Hg vacuum (41 kPa absolute).
j. Turn off the pumpout compressor.
k. Close valves 1a, 1b, 2, 5, and 6.
OIL
HEATER
ENTERING
WATER
2
C
b. Turn off the pumpout condenser water, and turn on
the pumpout compressor in manual mode to push
liquid refrigerant out of the storage tank. Monitor
the storage tank level until the tank is empty.
c. Close refrigerant charging valves 7 and 10.
d. Turn off the pumpout compressor.
e. Turn off the chiller water pumps.
f. Close valves 3 and 4.
g. Open valves 2 and 5.
FRAME
ASSEMBLY
VALVE
4
1b
2. Transfer remaining refrigerant.
a. Close valve 5 and open valve 4.
Always run chiller cooler and condenser water pumps and
always charge or transfer refrigerant as a gas when chiller
vessel pressure is less than 35 psig (241 kPa). Below these
pressures, liquid refrigerant flashes into gas, resulting in
extremely low temperatures in the cooler/condenser tubes
and possibly causing tube freeze-up.
CONTROL
PANEL
1a
VALVE
CONDITION
1a
1b
2
C
3
4
C
5
6
7
10
11
2. Transfer the remaining liquid.
a. Turn off pumpout condenser water. Place valves in
the following positions:
VALVE
CONDITION
1a
1b
2
3
C
4
C
5
6
7
10
11
b. Run the pumpout compressor in automatic mode
until vacuum switch is satisfied and compressor
stops. Close valves 7 and 10.
11
d. Gradually crack open valve 5 to increase chiller
pressure to 35 psig (241 kPa). Slowly feed refrigerant to prevent freeze-up.
e. Open valve 5 fully after the chiller pressure rises
above the freezing point of the refrigerant. Let the
storage tank and chiller pressure equalize. Open
refrigerant charging valve 7 and storage tank
VALVE
CONDITION
1a
1b
2
3
C
4
C
5
6
c. Turn off the pumpout compressor.
3. Remove any remaining refrigerant.
a. Turn on chiller water pumps.
b. Turn on pumpout condenser water.
70
7
C
10
C
11
This operation can be done in Automatic or On
mode. In Automatic mode, the compressor will
stop automatically at approximately 15 in. Hg
vacuum (51 kPa absolute).
c. Place valves in the following positions:
VALVE
CONDITION
1a
1b
2
C
3
4
5
C
6
7
C
10
C
11
d. Close valve 1a.
e. Turn off pumpout compressor.
f. Close valves 1b, 3, and 4.
d. Run the pumpout compressor until the chiller pressure reaches 35 psig (241 kPa); then, shut off the
pumpout compressor. Warm chiller condenser
water will boil off any entrapped liquid refrigerant
and chiller pressure will rise.
e. When chiller pressure rises to 40 psig (276 kPa),
turn on the pumpout compressor until the pressure
again reaches 35 psig (241 kPa), then, turn off the
pumpout compressor. Repeat this process until the
chiller pressure no longer rises; then, turn on the
pumpout compressor and pump out until the chiller
pressure reaches 18 in. Hg vacuum (41 kPa absolute). This can be done in On or Automatic mode.
f. Close valves 1a, 1b, 3, 4, and 6.
VALVE
CONDITION
1a
C
1b
C
2
C
3
C
4
C
5
C
6
C
7
C
10
C
VALVE
CONDITION
11
VALVE
CONDITION
1b
2
3
C
4
C
5
VALVE
CONDITION
11
1a
1b
2
C
3
4
5
C
3
C
4
C
5
C
11
C
1a
1b
2
3
C
4
C
5
11
1a
1b
2
3
C
4
C
5
11
C
c. Turn on pumpout condenser water.
d. Run the pumpout compressor until the chiller condenser reaches 18 in. Hg vacuum (41 kPa absolute)
in Manual or Automatic mode. Monitor pressure at
the chiller control panel and refrigerant gages.
e. Close valve 1b.
f. Turn off pumpout compressor.
g. Close valves 1a, 2, and 5.
c. Equalize the refrigerant in the chiller cooler and
condenser.
d. Turn off chiller water pumps and pumpout condenser water supply.
e. Turn on pumpout compressor to push liquid out of
the chiller cooler vessel.
f. When all liquid has been pushed into the chiller
condenser vessel, close the cooler refrigerant isolation valve (11).
g. Turn on the chiller water pumps.
h. Turn off the pumpout compressor.
2. Evacuate gas from chiller cooler vessel.
a. Close pumpout valves 2 and 5; open valves 3
and 4.
VALVE
CONDITION
2
C
c. Equalize the refrigerant in the chiller cooler and
condenser.
d. Turn off chiller water pumps and pumpout condenser water.
e. Turn on pumpout compressor to push refrigerant
out of the chiller condenser.
f. When all liquid is out of the chiller condenser,
close valve 11 and any other liquid isolation valves
on the chiller.
g. Turn off the pumpout compressor.
2. Evacuate gas from chiller condenser vessel.
a. Turn on chiller water pumps.
b. Make sure that pumpout valves 3 and 4 are closed
and valves 2 and 5 are open.
Transfer All Refrigerant to Chiller Condenser Vessel
1. Push refrigerant into chiller condenser vessel.
a. Turn on the chiller water pumps and monitor the
chiller pressure.
b. Valve positions:
1a
1b
C
g. Turn off pumpout condenser water.
h. Turn off chiller water pumps and lock out chiller
compressor.
Transfer All Refrigerant to Chiller Cooler Vessel
1. Push refrigerant into the chiller cooler vessel.
a. Turn on the chiller water pumps and monitor the
chiller pressure.
b. Valve positions:
g. Turn off the pumpout condenser water.
4. Establish vacuum for service. To conserve refrigerant,
operate the pumpout compressor as described in Step 3e
until the chiller pressure is reduced to 18 in. Hg
vacuum (41 kPa absolute).
This operation can be done in Automatic or On mode.
In Automatic mode, the compressor will stop automatically at approximately 15 in. Hg vacuum (51 kPa
absolute).
CHILLERS WITH ISOLATION VALVES — The valves referred to in the following instructions are shown in Fig. 31-33
and 41. Valve 7 remains closed.
VALVE
CONDITION
1a
C
VALVE
CONDITION
1a
C
1b
C
2
C
3
C
4
C
5
C
11
C
h. Turn off pumpout condenser water.
i. Turn off chiller water pumps and lock out chiller
compressor.
Return Refrigerant to Normal Operating Conditions
1. Be sure that the chiller vessel that was opened has been
evacuated.
2. Turn on chiller water pumps.
3. Open valves 1a, 1b, and 3.
11
C
b. Turn on pumpout condenser water.
c. Run pumpout compressor until the chiller cooler
vessel pressure reaches 18 in. Hg vacuum (41 kPa
absolute). Monitor pressures on the chiller control
panel and on refrigerant gages.
VALVE
CONDITION
71
1a
1b
2
C
3
4
C
5
C
11
C
Safety Data Sheet and the latest ASHRAE Safety Guide for
Mechanical Refrigeration to learn more about safe handling of
this refrigerant.
4. Crack open valve 5, gradually increasing pressure in the
evacuated chiller vessel to 35 psig (241 kPa). Feed refrigerant slowly to prevent tube freeze-up.
5. Leak test to ensure chiller vessel integrity.
6. Open valve 5 fully.
VALVE
CONDITION
1a
1b
2
C
3
4
C
5
HFC-134a will dissolve oil and some non-metallic materials, dry the skin, and, in heavy concentrations, may displace enough oxygen to cause asphyxiation. In handling
this refrigerant, protect the hands and eyes and avoid
breathing fumes.
11
C
7. Close valves 1a, 1b, 3, and 5.
8. Open chiller isolation valve 11 and any other isolation
valves, if present.
VALVE
CONDITION
1a
C
1b
C
2
C
3
C
4
C
5
C
Adding Refrigerant — Follow the procedures described
11
in the Charge Refrigerant into Chiller section, page 63.
9. Turn off chiller water pumps.
DISTILLING THE REFRIGERANT
1. Transfer the refrigerant from the chiller to the pumpout
storage tank as described in the Transfer the Refrigerant
from Chiller to Pumpout Storage Tank section.
2. Equalize the refrigerant pressure.
a. Turn on chiller water pumps and monitor chiller
pressures.
b. Close pumpout and storage tank valves 2, 4, 5, and
10, and close chiller charging valve 7; open chiller
isolation valve 11 and any other chiller isolation
valves, if present.
c. Open pumpout and storage tank valves 3 and 6;
open chiller valves 1a and 1b.
VALVE
CONDITION
1a
1b
2
C
3
4
C
5
C
6
7
C
10
C
Always use the compressor pumpdown function in the
Control Test mode to turn on the evaporator pump and lock
out the compressor when transferring refrigerant. Liquid
refrigerant may flash into a gas and cause possible freezeup when the chiller pressure is below 35 psig (241 kPa).
Removing Refrigerant — If the optional pumpout sys-
tem is used, the 23XRV refrigerant charge may be transferred
to a storage vessel or within the condenser or cooler if isolation
valves are present. Follow procedures in the Pumpout and
Refrigerant Transfer Procedures section when removing refrigerant from the storage tank to the chiller.
Adjusting the Refrigerant Charge — If the addition or removal of refrigerant is required for improved chiller
performance, follow the procedures given under the Trim
Refrigerant Charge section, on this page.
11
d. Gradually crack open valve 5 to increase chiller
pressure to 35 psig (241 kPa). Slowly feed refrigerant to prevent freeze-up.
e. Open valve 5 fully after the chiller pressure rises
above the freezing point of the refrigerant. Let the
storage tank and chiller pressure equalize.
3. Transfer remaining refrigerant.
a. Close valve 3.
b. Open valve 2.
VALVE
CONDITION
1a
1b
2
3
C
4
C
5
6
7
C
10
C
Refrigerant Leak Testing — Because HFC-134a is
above atmospheric pressure at room temperature, leak testing
can be performed with refrigerant in the chiller. Use an electronic leak detector, halide leak detector, soap bubble solution,
or ultra-sonic leak detector. Be sure that the room is well ventilated and free from concentration of refrigerant to keep false
readings to a minimum. Before making any necessary repairs
to a leak, transfer all refrigerant from the leaking vessel. The
chiller should be leak tested at least once per year.
Refrigerant Leak Rate — ASHRAE recommends that
chillers should be immediately taken off line and repaired if the
refrigerant leakage rate for the entire chiller is more than 10%
of the operating refrigerant charge per year.
Additionally, Carrier recommends that leaks totalling less
than the above rate but more than a rate of 1 lb (0.5 kg) per year
should be repaired during annual maintenance or whenever the
refrigerant is pumped over for other service work.
11
c. Turn on pumpout condenser water.
d. Run the pumpout compressor until the storage tank
pressure reaches 5 psig (34 kPa), 18 in. Hg vacuum
(41 kPa absolute) in Manual or Automatic mode.
e. Turn off the pumpout compressor.
f. Close valves 1a, 1b, 2, 5, and 6.
g. Turn off pumpout condenser water.
VALVE
CONDITION
1a
C
1b
C
2
C
3
C
4
C
5
C
6
C
7
C
10
C
Test After Service, Repair, or Major Leak — If
all refrigerant has been lost or if the chiller has been opened for
service, the chiller or the affected vessels must be pressured
and leak tested. Refer to the Leak Test Chiller section to perform a leak test.
REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test procedures.
TO PRESSURIZE WITH DRY NITROGEN — Another
method of leak testing is to pressure with nitrogen only and use
soap bubble solution or an ultrasonic leak detector to determine
if leaks are present. This should only be done if all refrigerant
has been evacuated from the vessel.
1. Connect a copper tube from the pressure regulator on the
cylinder to the refrigerant charging valve. Never apply
full cylinder pressure to the pressurizing line. Follow the
listed sequence.
11
4. Drain the contaminants from the bottom of the storage
tank into a container. Dispose of contaminants safely.
GENERAL MAINTENANCE
Refrigerant Properties — HFC-134a is the standard
refrigerant in the 23XRV chiller. At normal atmospheric pressure, HFC-134a will boil at –14 F (–25 C), and must, therefore,
be kept in pressurized containers or storage tanks. The refrigerant is practically odorless when mixed with air. HFC-134a is
non-combustible at atmospheric pressure. Read the Material
72
2. Open the charging valve fully.
3. Slowly open the cylinder regulating valve.
4. Observe the pressure gage on the chiller and close the
regulating valve when the pressure reaches test level. Do
not exceed 140 psig (965 kPa).
5. Close the charging valve on the chiller. Remove the copper tube if no longer required.
SCHEDULED MAINTENANCE
Establish a regular maintenance schedule based on the actual chiller requirements such as chiller load, run hours, and cooler and condenser liquid quality. The time intervals listed in this
section are offered as guides to service only.
Service Ontime — The ICVC will display a SERVICE
ONTIME value on the MAINSTAT table. This value should be
reset to zero by the service person or the operator each time
major service work is completed so that time between service
can be seen.
Repair the Refrigerant Leak, Retest, and
Apply Standing Vacuum Test — After pressurizing
the chiller, test for leaks with a soap bubble solution, an electronic leak detector, a halide torch, or an ultrasonic leak detector. Bring the chiller back to atmospheric pressure, repair any
leaks found, and retest.
After retesting and finding no leaks, apply a standing vacuum test. Then dehydrate the chiller. Refer to the Chiller Dehydration in the Before Initial Start-Up section, page 55.
Inspect the Control Center — Maintenance is generally limited to general cleaning and tightening of connections.
Vacuum the control center enclosure to eliminate dust build-up.
In the event of chiller control malfunctions, refer to the Troubleshooting Guide section for control checks and adjustments.
Power connections on newly installed equipment may relax
and loosen after a month of operation. Turn off power and
re-tighten, check annually thereafter.
Trim Refrigerant Charge — If it becomes necessary
to adjust the refrigerant charge to obtain optimum chiller performance, operate the chiller at design load and then add or remove refrigerant slowly until the difference between LEAVING CHILLED LIQUID chilled liquid temperature and the
EVAP REFRIG LIQUID TEMP reaches design conditions. Do
not overcharge. For superheat information, see the Troubleshooting section on page 78.
Refrigerant may be added either through the optional storage tank or directly into the chiller as described in the section
entitled, Refrigerant Charging.
To remove any excess refrigerant, follow the procedure in
Transfer Refrigerant from Chiller to Pumpout Storage Tank
section, Steps 1a, b on page 70.
Be sure power to the control center is off when cleaning
and tightening connections inside the control center.
Check Safety and Operating Controls
Monthly — To ensure chiller protection, the Automated
Control Test in the service menu should be done at least once
per month. See Table 5 for safety control settings.
Do not manually open the oil reclaim isolation valve when
the chiller is shut down. Doing so will flood the vaporizer
with refrigerant and severely degrade the viscosity of the
oil in the sump.
WEEKLY MAINTENANCE
Check the Lubrication System — Mark the oil level on the oil sump sight glasses and observe the level each
week while the chiller is running. Check the moisture indicator
on the motor cooling line.
If the level goes below the bottom of the oil sump sight
glass, the oil reclaim system will need to be checked for proper
operation. The oil reclaim system is operating properly if the
level in the oil sump increases after running the chiller near full
load with a 95 F or higher CONDENSER TEMPERATURE
for 1 hour. If additional oil is required, add it through the oil
charging valve (Fig. 2 and 3). A hand pump is required for adding oil against refrigerant pressure. The oil charge for the
23XRV chiller is 7.5 gallons (28 L).
The oil must meet Carrier’s specifications for the 23XRV
chillers. Refer to Changing Oil and Oil Filter section. Any oil
that is added should be logged by noting the amount and date
in Fig. 40 on page 68. Any oil that is added due to oil loss not
related to service will eventually return to the sump. Excess oil
must be removed when the level is above the top of the oil
sump sight glass.
A 530-watt oil sump heater is controlled by the PIC III to
maintain oil temperature above 140 F (60 C) or CALC EVAP
SAT TEMP plus 53 F (29.4 C) when the compressor is off
(see the Controls section on page 12). The ICVC StatusCOMPRESS table displays whether the heater is energized or
not. If the PIC III shows that the sump heater is energized, but
the sump is not heating up, the power to the oil sump heater
may be off or the oil level may be too low. Check the oil level,
the sump oil heater contactor voltage, and oil heater resistance.
The PIC III will not permit compressor start-up if the oil temperature is less than 140 F (60 C) or CALC EVAP SAT TEMP
plus 15 F (8.3 C), whichever is lower. The control will continue
with start-up only after the temperature is within limits.
Changing Oil and Oil Filter — If the OIL PRES-
SURE DELTA P approaches the 18 psid (124 kPad) LOW OIL
PRESSURE ALARM threshold, change oil filter as needed.
Otherwise, change the oil filter on a yearly basis.
Change the oil after the first year of operation. Then,
change the oil at least every three years, or as needed. However, if a continuous oil monitoring system is present and/or a
yearly oil analysis is performed, the time between oil changes
may be extended. See Oil Specification section on page 74 for
additional information.
Compressor oil is hygroscopic. Containers should remain
tightly sealed in a clean and dry environment to prevent
moisture absorption from the air.
The 23XRV oil pump and filter can be isolated to change
the oil filter and oil while the refrigerant remains inside the
chiller. Use the following procedure to change the oil and oil
filter (if required):
CHANGING OIL
1. Make sure the compressor is off and the CB1 main circuit
breaker for the control center is open.
2. Open the CB2 control power and oil heater circuit breaker in order to turn off the power to the oil heater.
73
• Pour Point (maximum) . . . . . . . . . . . . . . . . . . . –6 F (–21 C)
• Flash Point (minimum) . . . . . . . . . . . . . . . . . . 428 F (220 C)
• Moisture Content (maximum). . . . . . . . . . . . . . . . . . .50 ppm
• Acid Number (maximum) . . . . . . . . . . . 0.15 mg KOH/gram
• Critical Solution Temperature with HFC-134a (maximum)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . –8 F(–22 C)
3. Record the oil level observed in the oil sump sight glass.
Be sure the power to the oil heater is off when the oil sump
is drained. If the oil heater remains energized when the
sump is empty, it will overheat any residual oil on the heating element and become fouled. Overheating the elements
will also significantly reduce their useful life.
tightly sealed in a clean and dry environment to prevent
4. Connect an oil charging hose to the oil drain valve on the
strainer housing. See Fig. 3. Place the other end of the oil
charging hose in a clean container suitable for used oil. A
portion of the oil drained from the sump should be used
as an oil sample and should be sent to a laboratory for
proper analysis. Do not contaminate this sample.
5. Slowly open the drain valve in order to drain the oil from
the sump.
This oil (part number PP23BZ110001 [6x1 gal cans] and
PP23BZ110005 [1x5 gal can]) may be ordered from your local
Carrier representative.
Oil Heater — Inspect the oil heater for carbon build-up on
the heating element if an adequate oil sump temperature cannot
be maintained when the chiller is shut down. It may be necessary to temporarily install the heater element terminal cover to
provide additional leverage while threading the oil heater into
the sump. The sump oil heater elements must be positioned
vertically to allow proper heat convection. See Fig. 43 and 44.
The heater element must be installed with the word “TOP” on
the threaded fitting facing upward.
The oil sump is at high pressure. Relieve pressure slowly.
6. Charge new oil through the drain valve on the strainer
housing. A hand pump or portable electric oil pump will
be required to charge oil back into the oil sump against refrigerant pressure.
7. Add oil (approximately 7 gal [23 L]) until it returns to the
level noted in Step 3. The oil sight glass will not fill completely since a small amount of gas will be trapped inside
(even under vacuum conditions).
8. Apply power through the CB2 controls and oil heater
circuit breaker.
Changing Oil Filter
1. Make sure the compressor is off and the disconnect for
the compressor starter is open.
2. Close both oil filter isolation valves. See Fig. 43.
3. Place a container underneath the oil filter assembly.
4. When a Schrader valve is provided, use it to relieve the
pressure. Slowly open the drain plug, located on the
bottom of the oil filter housing, to relieve pressure. Do
not remove the plug.
5. Remove the filter canisters by unscrewing the retainer
nut. The filter may now be removed and disposed of
properly.
6. Install new oil filter. Install the new O-ring. Tighten the
retainer nut.
7. If a Schrader valve is supplied, evacuate the oil filter by
connecting the vacuum pump to the Schrader valve.
8. Slowly open the isolation valve located near the oil pump
to equalize the pressure. Fully open both oil filter isolation valves.
Refrigerant Filter/Drier — A refrigerant filter/drier, located on the motor cooling line, should be changed once per
year, or as necessary, if the condition of the filter indicates a
need for less or more frequent replacement (see Fig. 45). A
moisture indicator (dry eye) sight glass is located beyond the
filter/drier to indicate the concentration of moisture in the
refrigerant. If the moisture indicator indicates moisture, locate
the source of the liquid immediately by performing a thorough
leak check. Close the isolation valves on either side of the filter
drier. Use the Schrader valve to relieve pressure in the isolated
filter/drier. Replace the filter/drier and evacuate the isolated
section of tubing with a vacuum pump attached to the Schrader
valve.
Oil Strainers — The oil reclaim system has two strainers.
One is installed in the VFD refrigerant cooling line between the
cooler and condenser. The second strainer is located in the oil
sump strainer housing (see Fig. 43). The oil sump strainer must
be replaced or inspected with the refrigerant charge isolated in
the condenser. Inspect the oil sump strainer for obstructions or
damage every time the oil is changed. The strainer threads into
the oil sump strainer housing. Install a new strainer o-ring if the
entire strainer does not require replacement.
VFD Refrigerant Strainer — A refrigerant strainer is
located in the line that supplies refrigerant to the VFD. Three
isolation valves in the refrigerant cooling lines must be closed
before this strainer is changed. See Fig. 45.
Vaporizer Refrigerant Return Line Orifice —
There is a metering orifice where the refrigerant return line attaches to the vaporizer (see Fig. 43). This orifice can only be
inspected by cutting the vaporizer refrigerant return line near
the vaporizer. This orifice should be inspected if hot condenser
gas flow through the vaporizer appears to be obstructed.
Oil Specification — If oil is to be added, it must meet the
following Carrier specifications:
• Carrier Part Number. . . . . . . .PP23BZ110001 (6x1 gal cans)
. . . . . . . . . . . . . . . . . . . . . . . . . . .PP23BZ110005 (1x5 gal cans)
• Oil type . . . . . . . . . . . . . . . . . . . . .Inhibited polyolester-based
synthetic compressor lubricant suitable for use
in screw compressors where high viscosity
and compatibility with HFC-134a
refrigerants is required.
• ISO Viscosity Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
• Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.981
• Viscosity, cSt at 40 C (104 F) . . . . . . . . . . . . . . . . 198 to 242
cSt at 100 C (212 F) . . . . . . . . . . . . . . . . . 18 to 21
SSU at 100 F (38 C) . . . . . . . . . . . . . . .1005 ± 100
SSU at 210 F (99 C) . . . . . . . . . . . . . . . . . . .91 ± 7
Compressor Inlet Bearing Oil Orifice — The oil
line leading to the compressor lubrication block is connected to
the inlet bearing oil orifice. The orifice is pressed into a
standard reducer/expander fitting and protected by a 50 X 50
mesh screen (see Fig. 46). Compressor oil lines and fittings between the oil filter and compressor must be capped during disassembly to prevent contamination. Inspect the inlet bearing oil
orifice whenever the oil line between the oil filter and compressor is disconnected.
74
4. Apply thread locking adhesive (P/N 24221 [10 ml] or
24231 [50 ml]) the 3/8-in. - 16 bolts that hold the float
valve in place. See Fig. 47 for a view of the float valve
design. Inspect the orientation of the float slide pin. It
must be pointed toward the bubbler tube for proper
operation.
5. Apply gasket sealant (P/N 19XL680-002) to both sides of
new gasket when reinstalling cover.
Inspect Condenser Refrigerant Float System — Perform this inspection when the condenser is
opened for service. See Fig. 47.
1. Transfer the refrigerant into the cooler vessel or into a
pumpout storage tank.
2. Remove the float access cover.
3. Clean the chamber and valve assembly thoroughly. Be
sure the valve moves freely. Ensure that all openings are
free of obstructions.
OIL SUPPLY
LINE (TO
COMPRESSOR)
OIL PRESSURE
LEAVING FILTER
SENSOR
OIL RECLAIM
ACTUATOR
OIL PRESSURE
REGULATOR LINE
OIL FILTER
SCHRADER
VALVE
OIL RECLAIM
LINE ( FROM
COOLER)
VAPORIZER REFRIGERANT
RETURN ORIFICE
OIL SUMP
PRESSURE
SENSOR
OIL SUMP STRAINER
OIL FILTER
ISOLATION VALVE
OIL SUMP
TEMPERATURE
SENSOR
OIL FILTER
a23-1639
OIL PUMP
ISOLATION VALVE
OIL PUMP
JUNCTION BOX
Fig. 43 — Oil Sump Strainer and Filter
CONDENSER
GAS INLET
VAPORIZER HEATER
JUNCTION BOX
OIL RETURN
FROM COMPRESSOR
OIL
PRESSURE
REGULATOR
VALVE
OIL SUMP
TEMPERATURE
SENSOR
(ON FAR END
OF OIL SUMP)
a23-1630
OIL SUMP
SIGHT GLASS
VERTICALLY ORIENTED
OIL HEATER
ELEMENTS
VAPORIZER
TEMPERATURE
SENSOR THERMOWELL
OIL SUMP
HEATER
JUNCTION
BOX
Fig. 44 — Oil Reclaim Cross Section
75
VAPORIZER
DRAIN SIGHT
GLASS
OIL PRESSURE
REGULATOR
ISOLATION VALVE
FILTER DRIER
ISOLATION VALVE
MOISTURE INDICATOR
VFD REFRIGERANT COOLING
ISOLATION VALVES (2)
VFD REFRIGERANT
STRAINER
REFRIGERANT
FILTER/DRIER
FILTER/DRIER
ISOLATION VALVE
a23-1616
Fig. 45 — Refrigerant Filter/Drier
1
ORIFICE SCREEN
2
3
4
a23-1631
5
Fig. 46 — Compressor Inlet Bearing Oil Orifice
6
7
a23-1632
1
2
3
4
5
6
7
8
—
—
—
—
—
—
—
—
8
LEGEND
Refrigerant Inlet from FLASC Chamber
Linear Float Assembly
Float Screen
Bubbler Line
Float Cover
Bubble Line Connection
Refrigerant Outlet to Cooler
Gasket
Fig. 47 — 23XRV Float Valve Design
76
Higher than normal condenser pressures, together with the
inability to reach full refrigeration load, usually indicate dirty
tubes or air in the chiller. If the refrigeration log indicates a rise
above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser liquid temperature. If this reading is more than what the design difference is
supposed to be, then the condenser tubes may be dirty or liquid
flow may be incorrect. Because HFC-134a is a high-pressure
refrigerant, air usually does not enter the chiller.
During the tube cleaning process, use brushes especially
designed to avoid scraping and scratching the tube wall.
Contact your Carrier representative to obtain these brushes. Do
not use wire brushes.
Inspect Relief Valves and Piping — The relief valves
on this chiller protect the system against the potentially dangerous effects of overpressure. To ensure against damage to the
equipment and possible injury to personnel, these devices must
be kept in peak operating condition. Inspect the relief valves in
accordance with local codes.
At a minimum, the following maintenance is required.
1. At least once a year, disconnect the vent piping at the
valve outlet and carefully inspect the valve body and
mechanism for any evidence of internal corrosion or rust,
dirt, scale, leakage, etc.
2. If corrosion or foreign material is found, do not attempt to
repair or recondition. Replace the valve.
3. If the chiller is installed in a corrosive atmosphere or the
relief valves are vented into a corrosive atmosphere,
make valve inspections at more frequent intervals.
Hard scale may require chemical treatment for its prevention or removal. Consult a liquid treatment specialist for
proper treatment. Failure to properly treat liquid could
result in property damage or personal injury.
Compressor Bearing Maintenance — The compressor bearings are designed to last for the life of the chiller.
The key to good bearing maintenance is proper lubrication.
Use the proper grade of oil, maintained at recommended level,
temperature, and pressure. Inspect the lubrication system
regularly and thoroughly.
Excessive bearing wear can be detected through increased
vibration. If this symptom appears, contact an experienced and
responsible service organization to perform vibration analysis
on the compressor.
Water/Brine Leaks — Moisture in the refrigerant is in-
dicated during chiller operation by the refrigerant moisture
indicator on the refrigerant motor cooling line. See Fig. 2.
Leaks should be repaired immediately.
The chiller must be dehydrated after repair of liquid leaks.
See Chiller Dehydration section, page 55. Failure to dehydrate the chiller after repair of liquid leaks could result in
equipment damage or personal injury.
Compressor Rotor Check — Use Carrier specified
oil. Excessive compressor rotor wear is shown by a lack of
performance. If a lack of performance is noted, have the
compressor rotors inspected by a trained service person.
The rotors can be visually inspected once every 5 to
10 years or as needed depending on chiller operating
conditions.
Water/Brine Treatment — Untreated or improperly
treated water/brine may result in corrosion, scaling, erosion, or
algae. The services of a qualified water/brine treatment specialist should be obtained to develop and monitor a treatment
program.
Motor Insulation — Periodic checks of the motor insulation are not necessary. A 500V megger test is recommended to
assist troubleshooting if there are indications of problems
including, but not limited to, moisture in the refrigerant, and
chronic current imbalance or over current trips. See guidelines
for megger test in the Before Initial Start-Up section on
page 48.
Water/brine must be within design flow limits, clean, and
treated to ensure proper chiller performance and to reduce
the potential of tubing damage due to corrosion, scaling,
erosion, and algae. Carrier assumes no responsibility for
chiller damage resulting from untreated or improperly
treated water/brine.
The motor leads must be disconnected from the VFD
before an insulation test is performed. The voltage generated from the test equipment can damage the solid-state
VFD components.
Inspect the Control Center — Before working on
any starter, shut off the chiller, open and tag all disconnects
supplying power to the control center.
Inspect the Heat Exchanger Tubes
COOLER — Inspect and clean the cooler tubes at the end of
the first operating season. Because these tubes have internal
ridges, a rotary-type tube cleaning system is necessary to fully
clean the tubes. Upon inspection, the tube condition will determine the scheduled frequency for cleaning, and will indicate
whether liquid treatment is adequate in the chilled liquid/
brine circuit. Inspect the entering and leaving chilled liquid
temperature sensors for signs of corrosion or scale. Replace the
sensor if corroded or remove any scale if found.
CONDENSER — Since this liquid circuit is usually an opentype system, the tubes may be subject to contamination and
scale. Clean the condenser tubes with a rotary tube cleaning
system at least once per year and more often if the liquid is
contaminated. Inspect the entering and leaving condenser liquid sensors for signs of corrosion or scale. Replace the sensor if
corroded or remove any scale if found.
Before working on any VFD, shut off the chiller, open and
tag all disconnects supplying power to the starter. After disconnecting input power to a VFD and before touching any
internal components, wait 5 minutes for the DC bus capacitors to discharge, then check the voltage with a voltmeter.
Failure to observe this warning could result in severe
bodily injury or death.
The disconnect on the front of the control center does not
deenergize all internal circuits. Open all internal control
power and remote disconnects before servicing the starter.
77
Relieve refrigerant pressure and add oil to the pumpout unit
as follows:
1. Refer to Fig. 41. Close service valves 2 and 4.
2. Run the pumpout compressor in Automatic mode for one
minute or until the vacuum switch is satisfied and compressor shuts off.
3. Move the pumpout selector switch to OFF. Pumpout
compressor shell should now be under vacuum.
4. Oil can be added to the shell with a hand oil pump
through the access valve in the compressor base.
NOTE: Compressor access valve has a self-sealing fitting
which will require a hose connection with a depressor to open.
The motor leads must be disconnected from the VFD
before an insulation test is performed. The voltage generated from the tester can damage the drive components.
Never open isolating knife switches while equipment is
operating. Electrical arcing can cause serious injury.
Periodically vacuum or blow off accumulated debris on the
internal parts with a high-velocity, low-pressure blower.
Power connections on newly installed control centers may
relax and loosen after a month of operation. Turn power off and
retighten. Recheck annually thereafter.
OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS
(Fig. 48) — The optional pumpout system high-pressure
switch should open at 185 psig (1276 kPa) and closes automatically at 140 psig (965 kPa). Check the switch setting by
operating the pumpout compressor and slowly throttling the
pumpout condenser liquid.
Ordering Replacement Chiller Parts — When ordering Carrier specified parts, the following information must
accompany an order.
• chiller model number and serial number
• VFD model number and serial number (if applicable)
• name, quantity, and part number of the part required
• delivery address and method of shipment
Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures.
Recalibrate Pressure Transducers — Once a year,
the pressure transducers should be checked against a pressure
gage reading. Check all transducers (up to 9): the oil pressure
delta P transducers, discharge pressure transducer, the condenser pressure transducer, the cooler pressure transducer, and the
optional liquidside pressure transducers (consisting of 4 optional flow devices: 2 cooler, 2 condenser).
Note the evaporator and condenser pressure readings on the
HEAT_EX screen (EVAPORATOR PRESSURE and
CONDENSER PRESSURE). Attach an accurate set of refrigeration gages to the cooler and condenser Schrader fittings.
Compare the two readings. If there is a difference in readings,
the transducer can be calibrated as described in the Troubleshooting Guide section. Oil differential pressure (OIL PRESSURE DELTA P on the COMPRESS screen) should be close to
zero whenever the compressor is off. The oil pressure delta P
transducers indicate the difference between oil pressure leaving
filter and oil sump pressure.
CONTACTOR
TERMINAL
STRIP
FUSES
SWITCH
Optional Pumpout System Maintenance — For
pumpout unit compressor maintenance details, refer to the
19XR Positive Pressure Storage System Installation, Start-Up,
and Service Instructions.
OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —
Use oil conforming to Carrier specifications for reciprocating
compressor usage. Oil requirements are as follows:
• HFC-134a ISO Viscosity . . . . . . . . . . . . . . . . .68 or 220
• Viscosity SSU 100 F (38 C) . . . . . . . . . . . . .300 or 1005
• Carrier Part Number . . PP23BZ-103 or PP23BZ110005
The total oil charge is 13 oz (0.5 L).
a23-1569
TRANSFORMER
CONTROL BOX (INTERIOR)
Fig. 48 — Optional Pumpout System Controls
TROUBLESHOOTING GUIDE
Overview — The PIC III has many features to help the operator and technician troubleshoot a 23XRV chiller.
• The ICVC shows the chiller’s actual operating conditions
and can be viewed while the unit is running.
• The ICVC default screen freezes when an alarm occurs.
The freeze enables the operator to view the chiller conditions at the time of alarm. The STATUS screens continue
to show current information. Once all alarms have been
cleared (by correcting the problems and pressing the
RESET softkey), the ICVC default screen returns to
normal operation.
tightly sealed in clean and dry environments to prevent
Oil should be visible in the pumpout compressor sight glass
both during operation and at shutdown. Always check the oil
level before operating the pumpout compressor. Before adding
or changing oil, relieve the refrigerant pressure through the
access valves.
78
The resistance and corresponding temperature are listed in
Table 17A or 17B. Check the resistance of both wires to
ground. This resistance should be infinite.
VOLTAGE DROP — The voltage drop across any energized
sensor can be measured with a digital voltmeter while the
control is energized. Table 17A or 17B lists the relationship
between temperature and sensor voltage drop (volts dc
measured across the energized sensor). Exercise care when
measuring voltage to prevent damage to the sensor leads,
connector plugs, and modules. Sensors should also be checked
at the sensor plugs. Check the sensor wire at the sensor for
5 vdc if the control is powered on.
CHECK SENSOR ACCURACY — Place the sensor in a
medium of known temperature and compare that temperature
to the measured reading. The thermometer used to determine
the temperature of the medium should be of laboratory quality
with 0.5º F (.25º C) graduations. The sensor in question should
be accurate to within 2º F (1.2º C).
See Fig. 3 for sensor locations. Temperature sensors are
inserted into a thermowell in the refrigerant or liquid circuits.
When installing a new sensor thermowell, apply a pipe sealant
or thread sealant (RCD part number 56507) to the thermowell
threads. Coat the temperature sensors with thermally conductive grease (RCD Part Number PP8024) before inserting into
the thermowell.
DUAL MOTOR TEMPERATURE SENSORS — For servicing convenience, there are 2 sensors on the motor temperature
sensor. If one of the sensors is damaged, the other can be used
by simply moving a wire. The number 2 terminal in the sensor
terminal box is the common line. To use the second sensor,
move the wire from the number 1 position to the number
3 position.
• The CONTROL ALGORITHM STATUS screens (which
include the CAPACITY, OVERRIDE, LL_MAINT,
VFD_HIST, CUR_ALRM, LOADSHED, WSMDEFME,
and OCCDEFCM screens) display information that helps to
diagnose problems with chilled liquid temperature control,
chilled liquid temperature control overrides, hot gas bypass,
surge algorithm status, and time schedule operation. Refer
to Table 14.
• The CONTROL TEST screen under the SERVICE menu
facilitates the proper operation and test of temperature
sensors, pressure transducers, oil reclaim output, head
pressure output, oil pump, liquid pumps, tower control, and
other discrete on/off outputs while the compressor is
stopped. It also has the ability to lock out the compressor
and turn on liquid pumps for pumpout operation. The ICVC
shows the temperatures and pressures required during these
operations.
• From other SERVICE tables, the operator or technician can
access configured items, such as chilled liquid temperature
resets, override set points, etc.
• If an operating fault is detected, an alarm or alert message is
generated and displayed on the ICVC default screen. A
more detailed message — along with a diagnostic message
— is also stored into the ALARM HISTORY and ALERT
HISTORY tables. Refer to Tables 15 and 16.
• Review the ALERT HISTORY table to view other less critical events and abnormal conditions which may have
occurred. Compare timing of relevant alerts and alarms.
Checking Display Messages — The first area to
check when troubleshooting the 23XRV chiller is the ICVC
display. If the alarm light is flashing, check the primary and
secondary message lines on the ICVC default screen (Fig. 15).
These messages will indicate where the fault is occurring.
These messages contain the alarm message with a specified
code. This code or state appears with each alarm and alert message. The ALARM and ALERT HISTORY tables on the ICVC
SERVICE menu also contain a message to further expand on
the fault condition. Note that the date format in these tables is
MM/DD/YY. For a complete list of possible alarm messages,
see Table 16. If the alarm light starts to flash while accessing a
menu screen, press the EXIT softkey to return to the default
screen to read the alarm message. The STATUS screen can also
be accessed to determine where an alarm exists. A “C” to the
right of a parameters value means there is a communications
fault on that channel.
Checking Pressure Transducers — There are as
many as 9 pressure transducers on 23XRV chillers. They determine EVAPORATOR PRESSURE, CONDENSER PRESSURE, oil pressure leaving filter, oil sump pressure,
DISCHARGE PRESSURE, and optional CHILLED LIQUID
DELTA P and CONDENSER LIQUID DELTA P. The
EVAPORATOR PRESSURE and CONDENSER PRESSURE
transducers are also used by the PIC III to determine the refrigerant temperatures. The oil pressure delta P (oil pressure
leaving filter – oil sump pressure) is calculated by the CCM.
All pressure transducers should be calibrated prior to initial
start-up. At high altitude locations, it is necessary to calibrate
the transducers to ensure the proper refrigerant temperature/
pressure relationship. Each transducer is supplied with 5 vdc
power from the CCM. If the power supply fails, a transducer
voltage reference alarm (239) is declared. If the transducer
reading is suspected of being faulty, check the TRANSDUCER
VOLTAGE REF supply voltage. It should be 5 vdc ± .5 v
displayed in CONTROL TEST under PRESSURE TRANSDUCERS. If the TRANSDUCER VOLTAGE REF. is correct,
the transducer should be recalibrated or replaced.
Also check that inputs on CCM J5-1 through J5-6 have not
been grounded and are not receiving anything other than a 4 to
20 mA signal.
Checking Temperature Sensors — Except for the
motor temperature sensors, all temperature sensors are installed
in thermowells. This eliminates the need to drain the refrigerant, oil, or liquid from the chiller to replace the sensor. All
temperature sensors are thermistor-type sensors. This means
that the resistance of the sensor varies with temperature. All
sensors have the same resistance characteristics.
RESISTANCE CHECK — Turn off the control power and,
from the module, disconnect the terminal plug of the sensor in
question. With a digital ohmmeter, measure sensor resistance
between receptacles as designated by the wiring diagram.
79
softkey to finish the calibration. Pressures at high
altitude locations must be compensated for, so the chiller
temperature/pressure relationship is correct.
COOLER CONDENSER PRESSURE TRANSDUCER
AND OPTIONAL LIQUIDSIDE FLOW DEVICE CALIBRATION — Calibration can be checked by comparing the
pressure readings from the transducer to an accurate refrigeration gage reading. These readings can be viewed or calibrated
from the HEAT_EX screen on the ICVC. The transducer can
be checked and calibrated at 2 pressure points. These calibration points are 0 psig (0 kPa) and between 25 and 250 psig
(173 and 1724 kPa). To calibrate these transducers:
1. Shut down the compressor, cooler, and condenser pumps.
NOTE: There should be no flow through the heat
exchangers.
2. Disconnect the transducer in question from its Schrader
fitting for cooler or condenser transducer calibration. For
oil pressure delta P, the optional cooler and condenser
liquid delta P, or flow device calibration, leave the transducer in place.
NOTE: If the cooler or condenser vessels are at 0 psig
(0 kPa) or are open to atmospheric pressure, the transducers can be calibrated for zero without removing the
transducer from the vessel.
3. Access the HEAT_EX screen and view the particular
transducer reading (the EVAPORATOR PRESSURE or
CONDENSER PRESSURE parameter on the HEAT_EX
screen). To calibrate oil pressure or liquidside flow
device, view the particular reading (CHILLED LIQUID
DELTA P and CONDENSER LIQUID DELTA P on the
HEAT_EX screen, and OIL PRESSURE DELTA P on the
COMPRESS screen). It should read 0 psi (0 kPa). If the
reading is not 0 psi (0 kPa), but within ± 5 psi (35 kPa),
the value may be set to zero by pressing the SELECT
softkey while the appropriate transducer parameter is
highlighted on the ICVC screen. Then press the ENTER
softkey. The value will now go to zero. No high end
calibration is necessary for OIL PRESSURE DELTA P,
optional CHILLED LIQUID DELTA P or CONDENSER LIQUID DELTA P or for flow devices.
The PIC III does not allow calibration if the transducer is
too far out of calibration. In this case, a new transducer must be
installed and re-calibrated. If calibration problems are encountered on the OIL PRESSURE DELTA P channel, sometimes
swapping the oil pressure leaving filter and the oil sump
pressure transducer locations will offset an adverse transducer
tolerance stack up and allow the calibration to proceed.
TRANSDUCER REPLACEMENT — Since the pressure
transducers are mounted on Schrader-type fittings, there is no
need to remove refrigerant from the vessel when replacing the
transducers. Disconnect the transducer wiring by pulling up on
the locking tab while pulling up on the weather-tight connecting plug from the end of the transducer. Do not pull on the
transducer wires. Unscrew the transducer from the Schrader
fitting. When installing a new transducer, do not use pipe sealer
(which can plug the sensor). Put the plug connector back on the
sensor and snap into place. Check for refrigerant leaks.
Be sure to use a back-up wrench on the Schrader fitting
whenever removing a transducer, since the Schrader fitting
may back out with the transducer, causing a large leak and
possible injury to personnel.
Control Algorithms Checkout Procedure —
One of the tables on the ICVC SERVICE menu is CONTROL
ALGORITHM STATUS. The maintenance screens may be
viewed from the CONTROL ALGORITHM STATUS table to
see how a particular control algorithm is operating.
These maintenance screens are very useful in helping to
determine how the control temperature is calculated and for
observing the reactions from load changes, control point overrides, hot gas bypass, surge prevention, etc. See Table 14.
Table 14 — Control Algorithm
Maintenance Screens
If the transducer value is not within the calibration range,
the transducer returns to the original reading. If the pressure is within the allowed range (noted above), check the
voltage ratio of the transducer. To obtain the voltage ratio,
divide the voltage (dc) input from the transducer (white
wire to black wire) by the TRANSDUCER VOLTAGE
REF supply voltage signal (displayed in CONTROL
TEST menu in the PRESSURE TRANSDUCERS
screen). The TRANSDUCER VOLTAGE REF can be
measured across the positive (+ red) and negative
(– black) leads of the transducer. For example, the condenser transducer reference voltage is measured at CCM
terminals J2-4 (black) and J2-6 (red). The condenser
transducer input voltage is measured at CCM terminals
J2-4 (black) and J2-5 (clear or white). The input voltage
to reference voltage ratio must be between 0.80 and 0.11
for the software to allow calibration. Pressurize the
transducer until the ratio is within range, then attempt
calibration again.
4. A high pressure point can also be calibrated between 25
and 250 psig (172.4 and 1723.7 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a nitrogen cylinder). The high pressure point can be calibrated
by accessing the appropriate transducer parameter on the
HEAT_EX screen, highlighting the parameter, pressing
the SELECT softkey, and then using the INCREASE
or DECREASE softkeys to adjust the value to the exact
pressure on the refrigerant gage. Press the ENTER
SCREEN
CAPACITY
TITLE
Capacity
Control
OVERRIDE
Override
Status
LEAD/LAG
Status
VFD Alarm
History
Loadshed
Status
Current
Alarm Status
Liquid
System
Manager
Status
LL_MAINT
VFD_HIST
LOADSHED
CUR_ALRM
WSMDEFME
OCCDEFCM
Time
Schedules
Status
HEAT_EX*
HGBP
Status
DESCRIPTION
This table shows all values
used to calculate the chilled
liquid control point.
Details of all chilled liquid and
VFD control override values.
Indicates LEAD/LAG
operation status.
Displays VFD values at last
fault.
Displays Loadshed (Demand
Limit) status.
Displays current chiller
alarms.
The liquid system manager is
a CCN module that can turn
on the chiller and change the
chilled liquid control point. This
screen indicates the status of
this system.
The Local and CCN occupied
schedules are displayed here
to help the operator quickly
determine whether the
schedule is in the “occupied”
mode or not.
The hot gas bypass control
algorithm status is viewed
from this screen. All values
related to this control are
displayed.
*The HEAT_EX screen is under the STATUS menu.
80
vessels are isolated. The Terminate Lockout feature ends the
Pumpdown/Lockout after the pumpdown procedure is reversed
and refrigerant is added.
Control Test — The Control Test feature can check all the
thermistor temperature sensors, pressure transducers, pumps
and their associated flow devices, the oil reclaim output, the
head pressure output, and other control outputs such as tower
fans, VFD cooling solenoid, shut trip relay, oil heaters, alarm
relay, and hot gas bypass. The tests can help to determine
whether a switch is defective or if a pump relay is not operating, as well as other useful troubleshooting issues. During
pumpdown operations, the pumps are energized to prevent
freeze-up and the vessel pressures and temperatures are displayed. The Pumpdown/Lockout feature prevents compressor
start-up when there is no refrigerant in the chiller or if the
LEGEND FOR TABLES 15A-15J
CCM
CCN
ICVC
CHL
PIC III
VFD
WSM
—
—
—
—
—
—
—
Chiller Control Module
Carrier Comfort Network
Chilled Liquid
Product Integrated Control III
Water System Manager
Table 15 — ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides
A. MANUAL STOP
PRIMARY MESSAGE
MANUALLY STOPPED — PRESS
TERMINATE PUMPDOWN MODE
SECONDARY MESSAGE
CCN OR LOCAL TO START
TO SELECT CCN OR LOCAL
SHUTDOWN IN PROGRESS
COMPRESSOR UNLOADING
COMPRESSOR DEENERGIZED
ICE BUILD
OPERATION COMPLETE
RECYCLE RESTART PENDING
B. READY TO START
PRIMARY MESSAGE
READY TO START IN XX MIN
SECONDARY MESSAGE
UNOCCUPIED MODE
REMOTE CONTACTS OPEN
STOP COMMAND IN EFFECT
OCCUPIED MODE
REMOTE CONTACTS CLOSED
START COMMAND IN EFFECT
READY TO START
UNOCCUPIED MODE
READY TO START
REMOTE CONTACTS OPEN
READY TO START
STOP COMMAND IN EFFECT
READY TO START
READY TO START
READY TO START
OCCUPIED MODE
STARTUP INHIBITED
LOADSHED IN EFFECT
C. IN RECYCLE SHUTDOWN
PRIMARY MESSAGE
SECONDARY MESSAGE
OCCUPIED MODE
ICE BUILD MODE
PROBABLE CAUSE/REMEDY
PIC III in OFF mode, press CCN or LOCAL softkey to start unit.
Enter the CONTROL TEST table and select TERMINATE LOCKOUT
to unlock compressor.
Chiller unloading before shutdown due to soft/stop feature.
Chiller compressor is being commanded to stop. Liquid pumps are
deenergized within one minute.
Chiller shutdown from Ice Build operation.
Chiller is shutting down in recycle mode
Time schedule for PIC III is unoccupied. Chillers will start only when
occupied.
Remote contacts are open. Close contacts on Terminal Block TB1 to start.
Chiller START/STOP on MAINSTAT manually forced to stop.
Release force or send START force to start.
Chiller timer counting down. Unit ready to start.
Chiller timer counting down. Unit ready to start.
Remote contact enabled and closed.
The chiller will stop when the contacts are opened.
Chiller START/STOP on MAINSTAT manually forced to start.
Release force to start under normal control.
Chiller in recycle mode.
Time schedule for PIC III is unoccupied. Chiller will start when occupied.
Make sure the time and date are correct. Change values in TIME AND
DATE screen.
Remote contacts have stopped the chiller. Close contact on Terminal Block
TB1 to start.
Chiller START/STOP on MAINSTAT manually forced to stop. Release
point to start.
Chiller timer count down complete, unit start will commence.
Chiller timer count down complete. Unit ready for start.
Chiller START/STOP on MAINSTAT has been manually forced to start.
Chiller will start regardless of time schedule or remote contact status.
CCN loadshed module commanding chiller to stop.
Unit in recycle mode, chilled liquid temperature is not sufficiently above
set point to start.
Unit in recycle mode, chilled liquid temperature is not sufficiently above
set point to start.
Chiller START/STOP on MAINSTAT manually forced to start, chilled
liquid temperature is not sufficiently above set point to start.
Chiller in ICE BUILD mode. Chilled liquid temperature is satisfied for ICE
BUILD conditions.
81
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
D. PRE-START ALERTS: These alerts are only declared after a start command is issued and only delay start-up. When alert is corrected, the start-up will
continue. No reset is necessary.
PRIMARY
SECONDARY
MESSAGE
MESSAGE
PRESTART STARTS LIMIT
ALERT
EXCEEDED
ALARM MESSAGE
PRIMARY CAUSE
100->Excessive compressor starts
(8 in 12 hours)
101
PRESTART HIGH RECTIFIER
ALERT
TEMP
101->Rectifier Temperature [VALUE]
exceeded limit of [LIMIT]*.
102
PRESTART HIGH MOTOR
ALERT
TEMPERATURE
102->Comp Motor Winding Temp
[VALUE] exceeded limit of [LIMIT]*.
103
PRESTART HIGH DISCHARGE
ALERT
TEMP
103->Comp Discharge Temp
104
PRESTART LOW REFRIGERANT
ALERT
TEMP
104->Evaporator Refrig Temp
105
PRESTART LOW OIL
ALERT
TEMPERATURE
105->Oil Sump Temp
106
PRESTART HIGH CONDENSER
ALERT
PRESSURE
106->Condenser Pressure
107
PRESTART
LOW LINE VOLTAGE
ALERT
107->Percent Line Voltage
108
PRESTART HIGH LINE VOLTAGE
ALERT
108->Percent Line Voltage
109
PRESTART HIGH INVERTER TEMP 109->Inverter Temperature
ALERT
STATE
100
ADDITIONAL CAUSE/REMEDY
Depress the RESET softkey if additional start is
required. Reassess start-up requirements.
Check RECTIFIER TEMPERATURE in POWER screen.
Check VFD refrigerant isolation valves.
Check VFD power module cooling fan.
Check RECTIFIER TEMP OVERRIDE in SETUP1 screen.
See Table 5.
Check COMP MOTOR WINDING TEMP in COMPRESS screen.
Check motor temperature sensors for wiring and accuracy.
Check motor cooling line for proper operation, or restrictions.
Check for excessive starts within a short time span.
Check MOTOR TEMP OVERRIDE in SETUP1 screen.
See Table 5.
Check COMP DISCHARGE TEMP in COMPRESS screen.
Allow Compressor Discharge Sensor to cool.
Check for Compressor Discharge sensor wiring and accuracy.
Check for excessive starts.
Check COMP DISCHARGE ALERT in SETUP1 screen.
See Table 5.
Check EVAPORATOR PRESSURE in HEATEX screen.
Check Evaporator Pressure transducer wiring and accuracy.
Check for low chilled fluid supply temperatures.
Check refrigerant charge.
Check REFRIG OVERRIDE DELTA T in SETUP1 screen.
See Table 5.
Check OIL SUMP TEMP in ICVC default screen.
Check Oil Sump Temperature sensor wiring and accuracy.
Check 1C oil heater contactor/relay and power.
Check oil level and oil pump operation. Confirm that oil
reclaim valve is closed when chiller is not running.
See Table 5.
Check oil heater element for carbon build-up.
Check CONDENSER PRESSURE in HEATEX screen.
Check Condenser Pressure transducer wiring and accuracy.
Check for high condenser liquid temperatures.
Check COND PRESS OVERRIDE in SETUP1 screen.
See Table 5.
Check Line Voltage in POWER screen
Check voltage supply.
Check voltage transformers. Consult power utility if voltage is low.
Check FU1, FU2, and FU3 in the VFD.
Check connectors on VFD Line Synch Printed Circuit Board.
See Table 5.
Check Line Voltage in POWER screen.
Check voltage supply.
Check power transformers.
Consult power utility if voltage is high.
See Table 5.
Check INVERTER TEMPERATURE in POWER screen.
Check VFD power module cooling fan.
Check INVERTER TEMP OVERRIDE in SETUP1 screen.
See Table 5.
*[LIMIT] is shown on the ICVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert. [VALUE] is the actual
pressure, temperature, voltage, etc., at which the control tripped.
82
E. START-UP IN PROGRESS
PRIMARY MESSAGE
STARTUP IN PROGRESS
SECONDARY MESSAGE
OCCUPIED MODE
REMOTE CONTACT
CLOSED
START COMMAND
IN EFFECT
CAUSE/REMEDY
Chiller is starting. Time schedule is occupied (OCCUPIED? = YES).
Chiller is starting. REMOTE CONTACTS OPTION is set to ENABLE.
Remote contacts input on terminal block TB1 terminals 23 and 24 are closed.
AUTORESTART IN PROGRESS
OCCUPIED MODE
REMOTE CONTACT
CLOSED
START COMMAND
IN EFFECT
Chiller is starting after power failure. Time schedule is occupied
(OCCUPIED? = YES).
Chiller is starting after power failure. REMOTE CONTACTS OPTION is set to
ENABLE. Remote contacts input on terminal block TB1 terminals 23 and 24
are closed.
Chiller is starting after power failure. CHILLER START/STOP on MAINSTAT
manually forced to START.
STARTUP IN PROGRESS
STARTUP IN PROGRESS
Chiller is starting. CHILLER START/STOP in MAINSTAT manually forced to START.
F. NORMAL RUN
PRIMARY MESSAGE
SECONDARY MESSAGE
CAUSE/REMEDY
Auto chilled liquid reset active based on external input. ENABLE RESET
TYPE =1. A non-zero temperature reset based on a 4-20 mA signal on
RUNNING — RESET ACTIVE
BY 4-20 mA SIGNAL
CCM J5-3 and J5-4 is being added to the SETPOINT to determine the
CONTROL POINT. See TEMP_CTL screen.
Auto chilled liquid reset active based on external input. ENABLE RESET TYPE =2.
A non-zero temperature reset based on the remote sensor signal on CCM J4-13
REMOTE TEMP SENSOR
and J4-14 is being added to the SETPOINT to determine the CONTROL POINT.
See TEMP_CTL screen.
Auto chilled liquid reset active based on cooler DT. ENABLE RESET TYPE =3.
A non-zero temperature reset based on the difference between the ENTERING
CHL TEMP DIFFERENCE
CHILLED LIQUID and LEAVING CHILLED LIQUID is being added to the
SETPOINT to determine the CONTROL POINT. See TEMP_CTL screen.
Default method of temperature control. ECL CONTROL OPTION = DSABLE.
Chiller capacity is being controlled so the LEAVING CHILLED LIQUID temperature
RUNNING — TEMP CONTROL
LEAVING CHILLED LIQUID
is being maintained within 1/2 of the CHILLED LIQUID DEADBAND on either side
of the CONTROL POINT. See TEMP_CTL screen.
Entering Chilled Liquid (ECL) control enabled. ECL CONTROL OPTION
= ENABLE. Chiller capacity is being controlled so the ENTERING CHILLED
ENTERING CHILLED LIQUID LIQUID temperature is being maintained within 1/2 of the CHILLED LIQUID
DEADBAND on either side of the CONTROL POINT. See TEMP_CTL screen.
Ramp Loading based on LEAVING CHILLED LIQUID or ENTERING CHILLED
TEMPERATURE RAMP
LIQUID is in effect. PULLDOWN RAMP TYPE = 0. Capacity inhibit is in effect
LOADING
because LEAVING CHILLED LIQUID or ENTERING CHILLED LIQUID has fallen
below the ramping temperature pulldown setpoint. See RAMP_DEM screen.
Ramp Loading based on PERCENT LINE CURRENT or PERCENT LINE
BY DEMAND RAMP
KILOWATTS is in effect. PULLDOWN RAMP TYPE = 0. Capacity inhibit is in
RUNNING — DEMAND LIMITED LOADING
effect because PERCENT LINE CURRENT or PERCENT LINE KILOWATTS has
exceeded the ramping active demand limit. See RAMP_DEM screen.
Actual demand has exceeded ACTIVE DEMAND LIMIT. 20mA DEMAND LIMIT
BY LOCAL DEMAND
OPTION is DISABLED. ACTIVE DEMAND LIMIT is set equal to BASED DEMAND
RUNNING — DEMAND LIMITED SETPOINT
LIMIT. PERCENT LINE CURRENT or PERCENT LINE KILOWATTS is greater than
ACTIVE DEMAND LIMIT.
Actual demand has exceeded ACTIVE DEMAND LIMIT. 20mA DEMAND
LIMIT OPTION is ENABLED. ACTIVE DEMAND LIMIT is adjusted based on
RUNNING — DEMAND LIMITED BY 4-20 mA SIGNAL
4-20 mA signal received on CCM J5-1 and J5-2. PERCENT LINE CURRENT or
PERCENT LINE KILOWATTS is greater than ACTIVE DEMAND LIMIT.
Actual demand has exceeded ACTIVE DEMAND LIMIT. Chiller CONTROL
MODE = CCN. Value of ACTIVE DEMAND LIMIT is being forced by a CCN
RUNNING — DEMAND LIMITED BY CCN SIGNAL
device. PERCENT LINE CURRENT or PERCENT LINE KILOWATTS is greater
than ACTIVE DEMAND LIMIT.
Actual demand has exceeded ACTIVE DEMAND LIMIT. Chiller CONTROL
MODE = CCN. Value of ACTIVE DEMAND LIMIT was set equal to PERCENT
RUNNING — DEMAND LIMITED BY LOADSHED/REDLINE
LINE CURRENT or PERCENT LINE KILOWATTS at the time a Redline command
was received by the loadshed POC. PERCENT LINE CURRENT or PERCENT
LINE KILOWATTS is greater than ACTIVE DEMAND LIMIT. See LOADSHED screen.
HOT GAS BYPASS
HOT GAS BYPASS OPTION is set to ENABLE and HOT GAS BYPASS RELAY is ON.
RUNNING — DEMAND LIMITED BY LOCAL SIGNAL
ACTIVE DEMAND LIMIT has been manually forced on MAINSTAT screen.
ICE BUILD OPTION is set to ENABLE and chiller is running under Ice Build
ICE BUILD MODE
temperature control.
Actual demand has exceeded ACTIVE DEMAND LIMIT. Capacity inhibit is active
RUNNING — DEMAND LIMITED MOTOR LOAD CURRENT
because PERCENT LOAD CURRENT is greater than 100%.
Actual demand has exceeded ACTIVE DEMAND LIMIT. Capacity inhibit is active
RUNNING — DEMAND LIMITED VFD LINE CURRENT
because PERCENT LINE CURRENT exceeds 100%.
83
G. NORMAL RUN WITH OVERRIDES
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
ALARM MESSAGE
PRIMARY CAUSE
120
RUN CAPACITY
LIMITED
HIGH CONDENSER
PRESSURE
120->Condenser Pressure [VALUE]
121
RUN CAPACITY
LIMITED
HIGH MOTOR
TEMPERATURE
122
RUN CAPACITY
LIMITED
LOW EVAP REFRIG
TEMP
122->Evaporator Refrig Temp [VALUE]
123
RUN CAPACITY
LIMITED
HIGH RECTIFIER TEMP
123->Rectifier Temperature [VALUE]
exceeded limit of [LIMIT]*
124
RUN CAPACITY
LIMITED
MANUAL SPEED
CONTROL
125
RUN CAPACITY
LIMITED
HIGH INVERTER TEMP
126
RUN CAPACITY
OVERRIDE
COMP MIN SPEED IN
EFFECT
127
RUN CAPACITY
OVERRIDE
COMP MAX SPEED
LIMITED
125->Inverter Temperature [VALUE]
exceeded limit of [LIMIT]*
ADDITIONAL
CAUSE/REMEDY
Check for high condenser liquid temperatures.
Check COND PRESS OVERRIDE setting
in SETUP1.
Check motor cooling lines.
Check for closed valves.
Check COMP MOTOR TEMP OVERRIDE setting
in SETUP1.
Check REFRIG OVERRIDE DELTA T
setting in SETUP1 screen.
Check refrigerant charge.
Check for low entering cooler temperatures.
Check VFD refrigerant cooling solenoid valve.
Check RECTIFIER TEMP OVERRIDE in
SETUP1 screen.
TARGET VFD SPEED in COMPRESS screen is
forced to a fixed value.
Check VFD refrigerant cooling solenoid valve.
Check INVERTER TEMP OVERRIDE in
SETUP1 screen.
TARGET VFD SPEED is clamped to COMP
MINIMUM SPEED due to oil viscosity.
TARGET VFD SPEED is clamped to VFD
MAXIMUM SPEED.
Check VFD MAXIMUM SPEED in SETUP2 screen.
*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert,
or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control has recorded at the time of the fault condition.
H. OUT-OF-RANGE SENSOR ALARMS
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
ALARM MESSAGE
PRIMARY CAUSE
260
CHILLED
SENSOR FAULT LEAVING
LIQUID
260->Sensor Fault: Check Leaving
Chilled Liquid Sensor
261
CHILLED
SENSOR FAULT ENTERING
LIQUID
261->Sensor Fault: Check Entering
Chilled Liquid Sensor
262
SENSOR FAULT CONDENSER
PRESSURE
262->Sensor Fault: Check
Condenser Pressure Sensor
263
SENSOR FAULT EVAPORATOR
PRESSURE
Evaporator Pressure Sensor
264
PRESS SENSOR
SENSOR FAULT OIL
FAULT
264->Sensor Fault: Check Oil
Pressure Delta P Sensor
84
ADDITIONAL
CAUSE/REMEDY
Check sensor resistance or voltage drop against
Table 17A or 17B.
Check for proper wiring between Leaving Chilled
Liquid Temperature sensor and CCM.
Check for grounded sensor lead.
See Table 5.
Table 17A or 17B.
Check for proper wiring between Entering Chilled
Liquid Sensor and CCM.
See Table 5.
Confirm that 5V Reference voltage is available
on CCM.
Check sensor voltage drop.
Check for proper wiring between Condenser
Pressure Sensor and CCM.
Check for condensation inside of pressure
sensor connector.
See Table 5.
on CCM.
Check for proper wiring between Evaporator
Check for condensation inside of pressure sensor
connector.
See Table 5.
on CCM.
Check sensor voltage drops.
Check for proper wiring between Oil Sump
Pressure and Oil Pressure Leaving Filter Sensors
and CCM.
connectors.
See Table 5.
H. OUT-OF-RANGE SENSOR ALARMS (cont)
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
ALARM MESSAGE
PRIMARY CAUSE
266
SENSOR FAULT OIL SUMP TEMP
266->Sensor Fault: Check Oil Sump
Temp Sensor
267
DISCHARGE
SENSOR FAULT COMP
TEMP
267->Sensor Fault: Check Comp
Discharge Temp Sensor
268
SENSOR FAULT CHILLED LIQUID FLOW
268->Sensor Fault: Check Chilled
Liquid Delta P Sensor
269
SENSOR FAULT COND LIQUID FLOW
269->Sensor Fault: Check Cond
Liquid Delta P Sensor
270
REFRIG
SENSOR FAULT EVAP
LIQUID TEMP
270->Sensor Fault: Check Evap
Refrig Liquid Temp Sensor
271
SENSOR FAULT VAPORIZER TEMP
271->Sensor Fault: Check Vaporizer
Temp Sensor
272
SENSOR FAULT DISCHARGE
PRESSURE
272->Sensor Fault: Check Discharge
Pressure Sensor
85
ADDITIONAL
CAUSE/REMEDY
Table 17A or 17B.
Check for proper wiring between Oil Sump
See Table 5.
Table 17A or 17B.
Check for proper wiring between sensor and CCM.
See Table 5.
Check for 4.3 kohm load resistor on J3-14 and J3-15.
Check for jumper between J3-17 and J3-18.
on CCM.
See Table 5.
Check for proper wiring between optional Entering
Chilled Liquid Pressure and Leaving Chilled
Liquid Pressure Sensors and CCM.
Check for condensation inside of optional pressure
sensor connectors.
J3-17 to J3-18 jumper must be replaced with a
4.3 kohm resistor if optional flow switch is installed,
see Certified Prints.
Check for 4.3 kohm load resistor on J3-20 and J3-21.
Check for jumper between J3-23 and J3-24.
on CCM.
See Table 5.
Check for proper wiring between optional Entering
Condenser Liquid Pressure and Leaving Condenser
Liquid Pressure Sensors and CCM.
Check for condensation inside of optional pressure
sensor connectors.
J3-17 to J3-18 jumper must be replaced with a
4.3 kohm resistor if optional flow switch is installed,
see Certified Prints.
Table 17A or 17B.
Check for proper wiring between Evaporator Refrigerant
Liquid Temperature Sensor and CCM.
See Table 5.
Table 17A or 17B.
Check for proper wiring between Vaporizer
Temperature Sensor and CCM.
See Table 5.
on CCM.
Check for proper wiring between Compressor
Discharge Pressure Sensor and CCM.
connector.
See Table 5.
I. CHILLER PROTECTIVE LIMIT FAULTS
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
RECTIFIER POWER
FAULT
INVERTER POWER
FAULT
ALARM MESSAGE
PRIMARY CAUSE
200->Rectifier Power Fault:
Check VFD Status
201->Inverter Power Fault:
Check VFD Status
200
PROTECTIVE LIMIT
201
PROTECTIVE LIMIT
202
PROTECTIVE LIMIT
MOTOR AMPS NOT
SENSED
202->Motor Amps Not Sensed —
Average Load Current [VALUE]
203
FAILURE TO START
MOTOR
ACCELERATION
FAULT
203->Motor Acceleration Fault —
Average Load Current [VALUE]
204
FAILURE TO STOP
VFD SHUTDOWN
FAULT
204->VFD Shutdown Fault:
Check Inverter Power Unit
205
PROTECTIVE LIMIT
HIGH DC BUS
VOLTAGE
205->High DC Bus Voltage:
[VALUE] exceeded limit of
[LIMIT]*
206
PROTECTIVE LIMIT
VFD FAULT
206->VFD Fault Code: [VALUE];
Check VFD Fault Code List
207
PROTECTIVE LIMIT
HIGH CONDENSER
PRESSURE
207->High Cond Pressure trip.
[VALUE] exceeded Switch
Trippoint.
208
PROTECTIVE LIMIT
208->Percent Load Current
EXCESSIVE MOTOR [VALUE] exceeded limit of
AMPS
[LIMIT]*.
209
PROTECTIVE LIMIT
LINE CURRENT
IMBALANCE
209->Line Current Imbalance:
Check VFD Fault History for
Values.
210
PROTECTIVE LIMIT
LINE VOLTAGE
DROPOUT
210->Single Cycle Line
Voltage Dropout
211
PROTECTIVE LIMIT
HIGH LINE
VOLTAGE
211->High Percent Line
Voltage [VALUE]
212
PROTECTIVE LIMIT
LOW LINE
VOLTAGE
212->Low Percent Line
Voltage [VALUE]
213
PROTECTIVE LIMIT
VFD MODULE
RESET
213->VFD Module Power-On
Reset When Running
214
PROTECTIVE LIMIT
POWER LOSS
214->Control Power Loss
When Running
ADDITIONAL
CAUSE/REMEDY
Check VFD FAULT CODE in VFD_HIST screen.
See VFD FAULT CODES in Table 16.
Check main circuit breaker for trip.
Check MOTOR RATED LOAD AMPS
setting in VFD_CONF screen.
See Table 5.
Check starter for proper operation.
Reduce Condenser pressure if possible.
Check MOTOR RATED LOAD AMPS setting
in VFD_CONF screen.
See Table 5.
See Table 5.
Check DC BUS VOLTAGE and VFD FAULT
CODE in VFD_HIST screen.
Check for electrical continuity across
High Pressure Switch.
Check connections at VFD A33 Gate Kill Terminals.
Check for high condenser water temperatures,
low water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables in refrigerant.
Check Condenser Pressure transducer wiring
and accuracy.
See Table 5.
Check Load Currents in VFD_HIST screen.
Check MOTOR RATED LOAD AMPS setting
in VFD_CONF screen.
Check condenser water flow.
See Table 5.
Check LINE CURRENTs and VFD FAULT
Check LINE CURRENT IMBALANCE
settings in VFD_CONF screen.
Check power distribution bus.
Consult power company.
See Table 5.
Check LINE VOLTAGE and VFD FAULT
Check SINGLE CYCLE DROPOUT
See Table 5.
See Table 5.
Check distribution bus.
See Table 5.
Check LINE VOLTAGE in VFD_HIST screen.
Check control power voltage on ICVC terminal J1.
See Table 5.
*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an
override, alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
86
I. CHILLER PROTECTIVE LIMIT FAULTS (cont)
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
ALARM MESSAGE
PRIMARY CAUSE
215
PROTECTIVE LIMIT
LOW DC BUS
VOLTAGE
215->Low DC Bus Voltage:
[LIMIT]*
216
PROTECTIVE LIMIT
LINE VOLTAGE
IMBALANCE
216->Line Voltage Imbalance;
Values.
217
PROTECTIVE LIMIT
MOTOR OVERLOAD
TRIP
217->Motor Overload Trip;
Check VFD configurations
218
PROTECTIVE LIMIT
VFD RECTIFIER
OVERTEMP
218->VFD Rectifier Temp Exceeded:
Check Cooling and VFD Config.
219
PROTECTIVE LIMIT
VFD INVERTER
OVERTEMP
219->VFD Inverter Temp Exceeded:
Check Cooling and VFD Config.
220
PROTECTIVE LIMIT
GROUND FAULT
220->Ground Fault Trip;
Check Motor and Current Sensors
221
PROTECTIVE LIMIT
MOTOR ROTATION
REVERSED
221->Motor Rotation Reversed:
Check Wiring from VFD to Motor
222
PROTECTIVE LIMIT
LINE FREQUENCY
TRIP
222->Line Frequency [VALUE]:
Check Power Supply.
223
WITH VFD
LOSS OF COMMUNICATION GATEWAY
MODULE
224
PROTECTIVE LIMIT
VFD
COMMUNICATIONS
FAULT
224->Loss of DPI Comm with
VFD Gateway: Check VFG to
VFD Comm.
225
PROTECTIVE LIMIT
MOTOR CURRENT
IMBALANCE
225->Motor Current Imbalance:
Values.
226
PROTECTIVE LIMIT
LINE PHASE
REVERSAL
226->Line Phase Reversal:
Check Line Phases
227
PROTECTIVE LIMIT
OIL PRESS
SENSOR FAULT
227->Oil Pressure Delta P
[VALUE] (Pump Off): Check
Pump/Transducers
223->Loss of SIO Comm with
VFD Gateway: Check VFG
Module and Power
ADDITIONAL
CAUSE/REMEDY
See Table 5.
See Table 5.
Check LINE VOLTAGE IMBALANCE
Check LOAD CURRENT and VFD FAULT
See VFD FAULT CODEs in Table 16.
Check MOTOR RATED LOAD AMPS
in VFD_CONF screen.
See Table 5.
See Table 5.
Check VFD refrigerant isolation valves
and solenoid valve.
Check cooling fan on bottom of VFD
power module. Configure RECTIFIER
TEMP OVERRIDE in SETUP1 screen.
See Table 5.
Check VFD refrigerant isolation valves and
solenoid valve.
Check cooling fan on bottom of VFD
power module.
Configure INVERTER TEMP OVERRIDE
in SETUP1 screen.
Check GROUND FAULT CURRENT and
VFD FAULT CODE in VFD_HIST screen.
See Table 5.
Check if discharge pressure sensor is
out of range in CONTROL TEST screen.
See Table 5.
Check resistor between CCM J3-7 and J3-8.
Check LINE FREQUENCY and VFD FAULT
See Table 5.
Check SIO communication harness between the
Gateway and the J7 CCM connector.
Check status lights on CCM and Gateway
per Fig. 50 and 52.
Check ribbon cable and connectors between the
Gateway and the VFD DPI Communications
Interface Board per Fig. 50 and 52.
See Table 5.
Check MOTOR CURRENT IMBALANCE
See Table 5.
Select OIL PRESSURE DELTA P in
COMPRESS screen to calibrate sensors.
Check OIL SUMP PRESSURE and OIL
PRESSURE LEAVING FILTER pressure
transducer wiring and voltage drop.
Check oil line isolation valves.
87
STATE
PRIMARY
MESSAGE
SECONDARY
MESSAGE
ALARM MESSAGE
PRIMARY CAUSE
228
PROTECTIVE LIMIT
LOW OIL
PRESSURE
228->Low Operating Oil Pressure
[VALUE]: Check Oil Pump
and Filter
229
PROTECTIVE LIMIT
LOW CHILLED
LIQUID FLOW
229->Low Chilled Liquid Flow;
Check Switch/Delta P
Config & Calibration
230
PROTECTIVE LIMIT
LOW CONDENSER
LIQUID FLOW
230->Low Condenser Liquid
Flow; Check Switch/Delta P
Config & Calibration
231
PROTECTIVE LIMIT
HIGH DISCHARGE
TEMP
231->Comp Discharge Temp
[VALUE] Exceeded Limit of
[LIMIT]*
232
PROTECTIVE LIMIT
LOW REFRIGERANT 232->Evaporator Refrig Temp
TEMP
[LIMIT]*.
233
PROTECTIVE LIMIT
HIGH MOTOR
TEMPERATURE
VALUE] exceeded limit of
[LIMIT]*.
ADDITIONAL
CAUSE/REMEDY
Check oil level in Oil Sump sight glasses.
Check OIL SUMP PRESSURE and OIL
PRESSURE LEAVING FILTER transducer
wiring and voltage drop.
See Table 5.
Check power supply to pump and pump operation.
Look for oil flow through vaporizer drain
sight glass when chiller is running.
Check for partially closed isolation valves.
Check oil filter.
Check for foaming oil at start-up in oil sump.
Check OIL PRESSURE DELTA P transducer
calibration in COMPRESS screen.
Check vaporizer and oil sump heaters and
contactors.
Perform Pump Control Test in CONTROLS
TEST screen.
Check EVAP REFRIG LIQUID TEMP and
LEAVING CHILLER LIQUID sensor
accuracy and wiring.
See Table 5.
Check chilled liquid valves, pumps, and strainers.
Check EVAP REFRIG TRIPPOINT, EVAP
APPROACH ALERT, and EVAP FLOW DELTA P
CUTOUT, and LIQUID FLOW VERIFY TIME
settings.
Check optional liquid flow switches or liquid
delta P transducer calibration.
Perform Pump Control Test in CONTROLS
TEST screen.
See Table 5.
Check CONDENSER PRESSURE and LEAVING
COND LIQUID sensors accuracy and wiring.
Check condenser liquid valves, pumps,
and strainers.
Check COND APPROACH ALERT, COND
PRESS OVERRIDE, LIQUID FLOW VERIFY TIME,
and COND FLOW DELTA P CUTOUT settings.
Check optional liquid flow switches or liquid
delta P transducer calibration.
Check discharge isolation valve position.
See Table 5.
Check COMP DISCHARGE TEMP sensor
resistance or voltage drop.
Check for proper COMP DISCHARGE TEMP
sensor wiring.
Check for proper condenser flow and temperature.
Check for fouled tubes, plugged liquid strainers
or noncondensables in the system.
Alarm declared when chiller is running,
see Table 5.
Check Cooler Refrig Liquid Line Isolation
Valve Position.
Check for proper refrigerant charge.
Check Condenser Float Valve operation,
check if CHILLED LIQUID APPROACH
decreases when CONDENSER PRESSURE
increases.
Check EVAP APPROACH ALERT setting.
Check for proper fluid flow and temperature
against chiller design conditions.
Check COMP MOTOR WINDING TEMP
sensor wiring and accuracy.
See Table 5.
Check motor cooling line for proper operation,
restrictions, and isolation valve position.
Check motor cooling filter/drier and look for
refrigerant flow through motor cooling sight
glass.
Check for excessive starts within a
short time span.
The high motor temperature switch in the windings
or the motor temperature sensor circuit is open if
COMP MOTOR WINDING TEMP = 245 F(118 C).
88
STATE
234
235
236
237
238
239
240
241
242
243
244
PRIMARY
MESSAGE
SECONDARY
MESSAGE
ALARM MESSAGE
PRIMARY CAUSE
ADDITIONAL
CAUSE/REMEDY
Check for low oil level in oil sump sight glass.
See Table 5.
Refrigerant has not been adequately removed
LOW OIL
234->Low Prelube Oil Press [VALUE]: from the oil if bubbling can be observed through
PROTECTIVE LIMIT
PRESSURE
Check Oil Pump & Filter
oil sump sight glass.
Check vaporizer and oil sump heaters and
contactors.
Check OIL PRESS VERIFY TIME.
Check for high condenser liquid temperatures
See Table 5.
Check Condenser Approach in HEATEX screen.
Check for low liquid flow, plugged liquid strainers,
235->Condenser Pressure
HIGH CONDENSER [VALUE] exceeded limit of
and fouled tubes. Check for division plate/gasket
PROTECTIVE LIMIT
PRESSURE
bypass.
[LIMIT]*.
Check for noncondensables in refrigerant.
Check CONDENSER PRESSURE transducer
wiring and accuracy.
Configure COND PRESS OVERRIDE in
SETUP1 screen.
CCN has signaled the chiller to stop.
EMERGENCY STOP in the MAINSTAT
CCN
OVERRIDE
236->CCN
Emergency/Override
screen has been set to EMSTOP.
PROTECTIVE LIMIT
STOP
Stop
Reset and restart when ready. If the
signal was sent by the ICVC, release the
stop signal on the STATUS01 table.
Spare safety input has tripped or factory-installed
SPARE SAFETY
PROTECTIVE LIMIT
237->Spare Safety Device
jumper is not present between terminals 19 and
DEVICE
20 on the Low Voltage Field Wiring Terminal Strip.
Check condenser liquid flow and temperatures
See Table 5.
COMPRESSOR
238->Compressor Stall:
PROTECTIVE LIMIT
Check STALL TIME PERIOD and STALL %
MOTOR STALL
Check Compressor and Motor
AMPs settings.
Check for excessive refrigerant charge and
oil loss.
Check If CCM PRESSURE TRANSDUCER
VOLTAGE REFERENCE is less than 4.5 V
in CONTROLS TEST screen.
Confirm PRESSURE TRANSDUCER VOLTAGE
REFERENCE across a CCM Pressure Transducer
239->Transducer Voltage Ref
(e.g., CCM J3-1 to J3-3).
TRANSDUCER
PROTECTIVE LIMIT
Confirm that none of the transducers have
VOLTAGE FAULT
[LIMIT]*.
been shorted to ground.
Look for changes in voltage if customer wiring
to CCM J5-1 through J5-6 and J8-1 to J8-2 are
temporarily removed.
Check for 24 VAC across CCM terminals
J1-1 and J1-2.
ICVC and Gateway software compatibility numbers
240->VFD Gateway Compatibility
do not match. See ICVC SOFTWARE PART # in
COMPATIBILITY
VFD GATEWAY
Conflict: Check VFG/ICVC
ICVC CONFIGURATION SCREEN.
CONFLICT
Versions
See VFD GATEWAY VERSION # in VFD_STAT
screen.
RECTIFIER
241->Rectifier Overcurrent Fault:
PROTECTIVE LIMIT
OVERCURRENT
Check VFD Status
Check wiring and connectors between CCM
terminal J6 and ICVC terminal J7.
242->Loss of Communication
Check CCM status lights.
WITH
CCM
LOSS OF COMMUNICATION
With CCM: Check Comm.
Check for 24V control power to CCM J1-1
MODULE
Connectors
and J1-2.
Confirm that all CCM SW1 switches are in the
“off” position.
Alarm declared at power up and after chiller is
shutdown, see Table 5.
Check EVAPORATOR PRESSURE transducer.
243->Evaporator
Refrig
Temp
EVAP PRESS/TEMP
Check EVAP REFRIG TRIP POINT.
POTENTIAL FREEZE-UP
[VALUE]
exceeded
limit
of
TOO LOW
Check for proper refrigerant charge.
[LIMIT]*.
Check float operation.
Check for proper evaporator fluid flow
and temperature.
Alarm declared when chiller in shutdown,
COND PRESS/TEMP 244->Condenser Refrig Temp
see Table 5.
POTENTIAL FREEZE-UP
[VALUE]
exceeded
limit
of
TOO LOW
Check CONDENSER PRESSURE transducer.
[LIMIT]*.
Check CONDENSER FREEZE POINT setting.
89
PRIMARY
MESSAGE
SECONDARY
MESSAGE
245
PROTECTIVE LIMIT
VFD SPEED OUT
OF RANGE
245->Actual VFD Speed
exceeded limit of Target
VFD Speed ± 10%]*.
246
PROTECTIVE LIMIT
INVERTER
OVERCURRENT
246->Inverter Overcurrent Fault:
Check VFD Status
247
PROTECTIVE LIMIT
VFD START
INHIBIT
247->VFD Start Inhibit: Check
VFD Diagnostic Parameters
212/214
STATE
ALARM MESSAGE
PRIMARY CAUSE
248
PROTECTIVE LIMIT
SPARE
TEMPERATURE #1
248->Spare Temperature #1
[LIMIT]*.
249
PROTECTIVE LIMIT
SPARE
TEMPERATURE #2
249->Spare Temperature #2
[LIMIT]*.
250
PROTECTIVE LIMIT
REFRIGERANT
LEAK SENSOR
250->Refrigerant Leak
Sensor ppm [VALUE]
exceeded Limit of [LIMIT]*
251
PROTECTIVE LIMIT
VFD CONFIG
CONFLICT
251->VFD Config Conflict;
Verify & Save VFD Config
Data to Reset
253
PROTECTIVE LIMIT
VFD CHECKSUM
ERROR
253->Checksum Error:
Press Reset to Restore
Configuration
254
PROTECTIVE LIMIT
VFD DEW
PREVENTION
254->VFD Dew Prevention - VFD
Coolant too Cold, Check Solenoid
and Cond T
255
PROTECTIVE LIMIT
INDUCTOR
OVERTEMP
255->Inductor Overtemp
Trip - Check Temp Switch
and Cooling Fans
256
VFD GATEWAY
COMPATIBILITY
CONFLICT
256->VFD Gateway Compatibility
Conflict: Check VFG/VFD
Versions
ADDITIONAL
CAUSE/REMEDY
Check if ACTUAL VFD SPEED exceeds VFD
SPEED OUTPUT ±10% in COMPRESS
or CAPACITY screen.
See Table 5.
Check for VFD FAULT CODES in VFD_HIST screen.
Check LINE CURRENTs and VFD FAULT
Check component that SPARE TEMPERATURE #1
is monitoring.
See Table 5.
Check SPARE TEMPERATURE #1 settings
in SETUP1 screen.
Check SPARE TEMPERATURE #1 sensor
resistance or voltage drop on CCM terminals
J4-25 and J4-26.
Check SPARE TEMPERATURE #1 sensor wiring.
Check component that SPARE TEMPERATURE #2
is monitoring.
See Table 5.
Check SPARE TEMPERATURE #2 settings in
SETUP1 screen.
resistance or voltage drop on CCM terminals
J4-27 and J4-28.
Check SPARE TEMPERATURE #2 sensor wiring.
REFRIGERANT LEAK OPTION is enabled.
The refrigerant leak detector output wired to
CCM terminals J5-5 and J5-6 has reached
the alarm threshold (PPM AT 20 MA).
See Table 5.
Check for leaks.
Check leak detector.
Check REFRIGERANT LEAK OPTION, REFRIG
LEAK ALARM PPM and PPM AT 20 MA settings in
OPTIONS screen.
VFD Parameters stored in Gateway and ICVC
are not consistent.
Enter VFD_CONF screen and check settings stored
in ICVC against Machine Electrical Data Nameplate.
If parameter values are unacceptable,
exit VFD_CONF by pressing cancel. Re-enter
VFD_CONF screen and check settings uploaded
from Gateway against Machine Electrical Data
Nameplate. Press SAVE before exiting
VFD_CONF.
VFD inverter or rectifier checksum must
be regenerated.
Press RESET softkey on ICVC to restore
VFD configuration.
Reducing VFD COOLANT FLOW to 0% did not
adequately increase VFD COLDPLATE TEMP.
Check HUMIDITY SENSOR INPUT on CCM J3-7,
J3-9 and J4-10 and RELATIVE HUMIDITY in
POWER or CONTROLS TEST screen.
Check humidity sensor wiring on CCM.
Check VFD refrigerant cooling solenoid operation.
Increase Entering Condenser Liquid Temperature.
Reduce humidity surrounding chiller.
Check that VFD A34 NTC cold plate thermocouple is
wired to VFD A12 AC LINE I/O card TB1-19 and
TB1-20.
Temperature switch in VFD inductor has opened.
Middle Control Center door must be fully closed
to properly route airflow around VFD inductors.
Check wiring to inductor temperature switch.
Check inductor cooling fan operation.
Check for inductor cooling fan airflow obstructions.
VFD INVERTER VERSION # and/or VFD
RECTIFIER VERSION # are not compatible
with the GATEWAY VERSION #.
Check software version numbers in
VFD_STAT screen.
90
J. CHILLER ALERTS
STATE
PRIMARY MESSAGE
SECONDARY
MESSAGE
ALARM MESSAGE
PRIMARY CAUSE
140
SENSOR ALERT
LEAVING COND
LIQUID TEMP
Leaving Cond Liquid
Sensor
141
SENSOR ALERT
ENTERING COND
LIQUID TEMP
Sensor
142
SENSOR ALERT
LOW OIL
PRESSURE
142->Oil Pressure Delta P
[VALUE] Exceeded Limit of
[LIMIT]
143
AUTORESTART
PENDING
LINE CURRENT
IMBALANCE
143->Line Current
Imbalance:
Check VFD Fault History
for Values
144
AUTORESTART
PENDING
LINE VOLTAGE
DROP OUT
144->Single Cycle Line
Voltage Dropout
145
AUTORESTART
PENDING
HIGH LINE
VOLTAGE
145>High Percent Line
voltage [VALUE]
146
AUTORESTART
PENDING
LOW LINE
VOLTAGE
146->Low Percent Line
voltage [VALUE]
147
AUTORESTART
PENDING
VFD MODULE
RESET
147->VFD Module
Power-On Reset When
Running
148
AUTORESTART
PENDING
POWER LOSS
148->Control Power-Loss
When Running
149
AUTORESTART
PENDING
LOW DC BUS
VOLTAGE
149->Low DC Bus
Voltage: [VALUE]
Exceeded Limit of
[LIMIT]*
ADDITIONAL
CAUSE/REMEDY
Temperature sensor reading out of range.
Check LEAVING COND LIQUID TEMP sensor
resistance or voltage drop at CCM.
Check for grounded sensor leads.
Check for proper wiring.
See Table 5.
Temperature sensor reading out of range.
Check ENTERING COND LIQUID TEMP sensor
resistance or voltage drop at CCM.
Check for grounded sensor leads.
See Table 5.
Check for partially or closed oil line isolation
valves.
Check oil filter.
Check oil level.
Check Oil Pressure Leaving Filter and Oil Sump
Pressure transducer wiring and OIL PRESSURE
DELTA P accuracy.
See Table 5.
Chiller automatically restarting - AUTORESTART
OPTION is enabled.
Power loss has been detected in any phase.
Check LINE CURRENTs and VFD FAULT CODE
in VFD_HIST screen.
Check LINE CURRENT IMBALANCE settings in
VFD_CONF screen.
See Table 5.
Chiller is automatically restarting AUTORESTART OPTION is enabled.
A drop in line voltage has been detected within
2 voltage cycles.
Check LINE VOLTAGE and VFD FAULT CODE
in VFD_HIST screen.
See Table 5.
Check SINGLE CYCLE DROPOUT
in VFD_HIST screen.
See Table 5.
in VFD_HIST screen.
See Table 5.
VFD Module has detected a hardware fault
and has reset.
in VFD_HIST screen.
Check LINE VOLTAGE in VFD_HIST screen.
Check 24 vac control power voltage on ICVC
terminals J1-4 and J1-5.
See Table 5.
Check DC BUS VOLTAGE and VFD FAULT CODE
in VFD_HIST screen.
See Table 5.
*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator
as an override, alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
91
J. CHILLER ALERTS (cont)
STATE
PRIMARY MESSAGE
SECONDARY
MESSAGE
ALARM MESSAGE
PRIMARY CAUSE
150
AUTORESTART
PENDING
HIGH DC BUS
VOLTAGE
150->High DC Bus
Voltage: [VALUE]
Exceeded Limit of
[LIMIT]*
151
CONDENSER
PRESSURE
ALERT
PUMP RELAY
ENERGIZED
151->High Condenser
Pressure [VALUE]: Pump
Energized to
Reduce Pressure.
152
RECYCLE
ALERT
EXCESSIVE RECYCLE STARTS 152->Excessive
recycle starts.
153
no message:
ALERT only
no message;
ALERT only
153->Lead/Lag Disabled:
Duplicate Chiller Address;
Check Configuration
154
POTENTIAL
FREEZE-UP
COND PRESS/TEMP
TOO LOW
154->Condenser freeze
up prevention
155
OPTION
SENSOR FAULT
REMOTE RESET
SENSOR
155->Sensor Fault/Option
Disabled: Remote
Reset Sensor
156
OPTION
SENSOR FAULT
AUTO CHILLED
LIQUID RESET
Disabled: Auto Chilled
Liquid Reset
157
OPTION
SENSOR FAULT
AUTO DEMAND
LIMIT INPUT
Disabled: Auto Demand
Limit Input
158
SENSOR ALERT
SPARE
TEMPERATURE #1
158->Spare Temperature
#1 [VALUE] exceeded
limit of [LIMIT].*
159
SENSOR ALERT
SPARE
TEMPERATURE #2
159->Spare Temperature
#2 [VALUE] exceeded
limit of [LIMIT].*
ADDITIONAL
CAUSE/REMEDY
See Table 5.
Check input power for high voltage transients.
Check COND PRESS OVERRIDE in
SETUP1 screen.
Check CONDENSER PRESSURE sensor
wiring and accuracy.
Check condenser liquid flow, strainers,
and condenser liquid temperature.
Check for fouled tubes.
This alarm is not caused by the High
Pressure Switch.
Chiller load is too low to keep compressor on line
and there has been more than 5 starts in 4 hours.
Check HGBP Isolation valve position.
Increase chiller load.
Adjust hot gas bypass parameters in
OPTIONS screen.
Increase (RECYCLE CONTROL)
RESTART DELTA T in SETUP1 Screen.
Illegal chiller address configuration in
Lead/Lag screen, see Table 7.
Check chiller addresses in LEAD/LAG
and ICVC CONFIGURATION screens.
The chiller is not in pumpdown mode and the
condenser pressure transducer is reading a
pressure that could freeze the condenser tubes.
Check CONDENSER FREEZE POINT setting.
See Table 5.
Check for condenser refrigerant leaks.
Check condenser liquid temperature.
Check CONDENSER PRESSURE sensor wiring
and accuracy on CCM terminals J2-4, J2-5 and
J2-6.
Place the chiller in PUMPDOWN mode if the
vessel is evacuated.
Type 2 Temperature Reset is enabled and
Remote Reset sensor on CCM J4-13 and
J4-14 is out of range.
Check Temperature Reset settings in
TEMP_CNTL screen.
Check REMOTE RESET sensor resistance
or voltage drop.
Check for proper REMOTE RESET sensor wiring.
Type 1 Temperature Reset is enabled and Auto
Chilled Water Reset input on CCM J5-3 and
J5-4 is < 2 mA.
Check Temperature Reset settings in
TEMP_CNTL screen.
Check that Auto Chilled Liquid Reset input is
between 4 mA and 20 mA.
20 mA DEMAND LIMIT OPTION is enabled and
Auto Demand Limit input on CCM J5-1 and J5-2
is < 2 mA.
Check 20 mA DEMAND LIMIT setting in
RAMP_DEM screen.
Check that Auto Demand Limit input is between
4 mA and 20 mA.
Check component that SPARE TEMPERATURE
#1 is monitoring.
SETUP1 screen.
resistance or voltage drop on CCM J4-25 and
J4-26.
Check for proper SPARE TEMPERATURE
#1 wiring.
Check component that SPARE TEMPERATURE
#2 is monitoring.
SETUP1 screen.
resistance or voltage drop on CCM J4-27
and J4-28.
Check for proper SPARE TEMPERATURE
#2 wiring.
92
J. CHILLER ALERTS (cont)
STATE
PRIMARY MESSAGE
SECONDARY
MESSAGE
ALARM MESSAGE
PRIMARY CAUSE
160
SENSOR ALERT
EVAPORATOR
APPROACH
160->Evaporator
Approach [VALUE]
Exceeded Limit of
[LIMIT]*
161
SENSOR ALERT
CONDENSER
APPROACH
161->Condenser
Approach [VALUE]
Exceeded Limit of
[LIMIT]*
162
SENSOR ALERT
HIGH DISCHARGE
TEMP
162->Comp Discharge
Temp [VALUE] Exceeded
Limit of [LIMIT]*
163
LOSS OF
COMMUNICATION
WITH WSM
163->WSM Cool
Source - Loss of
Communication
164
SYSTEM ALERT
HIGH OIL
PRESSURE
164->High Oil Pressure
[VALUE], Check Oil
Regulator and Valves
168
SENSOR ALERT
HUMIDITY
SENSOR INPUT
168->Sensor Fault:
Check Humidity
Sensor Input
ADDITIONAL
CAUSE/REMEDY
Check position of refrigerant liquid
line isolation valve.
Check EVAP APPROACH ALERT setting in
SETUP1 screen.
Check Evaporator Liquid Flow.
See Table 5.
Check EVAP REFRIG LIQUID TEMP and
CHILLED LIQUID TEMP sensor resistances
or voltage drops.
Check for proper EVAP REFRIG LIQUID TEMP
and CHILLED LIQUID TEMP sensor wiring.
Check for oil loss.
Check for low refrigerant charge.
Check float valve operation and for refrigerant
stacking in the condenser.
Check for evaporator division plate bypass.
Check for fouled tubes.
Check for air in water box.
Check COND APPROACH ALERT setting in
SETUP1 screen.
Check Condenser Liquid flow.
See Table 5.
Check CONDENSER PRESSURE and LEAVING
COND LIQUID temperature sensor resistances or
voltage drops.
Check for proper CONDENSER PRESSURE and
LEAVING COND LIQUID temperature sensor
wiring.
Check condenser shell temperature against
condenser pressure measured with refrigerant
gage for evidence of non-condensables in
refrigerant charge.
Check for condenser division plate bypass.
Check for fouled condenser tubes.
Check for air in water box.
Check position of condenser isolation valve.
Check COMP DISCHARGE ALERT setting in
SETUP1 screen.
See Table 5.
Check COMP DISCHARGE TEMP sensor
resistance or voltage drop.
Check for proper condenser liquid flow and
temperature.
Check for fouled tubes, plugged strainers,
or non-condensables in the refrigerant.
Communications interrupted between
supervisory component and equipment
component of WSM (Water System Manager).
Check settings in WSMDEFME screen.
Check CCN communications link with WSM.
Check supervisory part of WSM.
See Table 5.
Check oil pressure regulator isolation valve.
Check oil pressure regulator.
Check for bent oil lines.
Check Oil Sump Pressure and Oil Pressure
Leaving filter transducer resistances or
voltage drops.
Check OIL PRESSURE DELTA P wiring to CCM.
Check for debris in Compressor Inlet Bearing
Oil Orifice Strainers.
Normal alert if chiller was charged and started
within a few hours of pulling dehydration vacuum
with oil heater on.
See Table 5.
Humidity Sensor Input voltage is outside of
0.5 V to 4.5 V range.
Check Humidity Sensor wiring to CCM terminals
J3-7, J3-9, and J4-10.
Check Humidity Sensor Input in Controls
Test screen.
Check resistance 4.3 kohm load resistor
between CCM J3-7 and J3-8.
93
Table 16 — Fault Description and Corrective Actions
FAULT
FAULT
CODE
2
Auxiliary Input
3
Power Loss
TYPE
DESCRIPTION
1
1, 3
Input is open.
DC bus voltage remained below 85% of
nominal for longer than Power Loss Time
(185).
Enable/disable with Fault Config 1 (238).
DC bus voltage fell below the minimum
value of 407V DC at 400/480V input.
DC bus voltage exceeded maximum
value.
4
UnderVoltage
1, 3
5
OverVoltage
1
7
Motor Overload
1, 3
8
Invtr Base Temp
1
9
Invtr IGBT Temp
1
12
HW OverCurrent
1
13
Ground Fault
1
24
Decel Inhibit
3
25
OverSpeed Limit
1
29
Analog In Loss
1, 3
33
Auto Rstrt Tries
3
35
Current Fbk Lost
4
36
SW OverCurrent
1
37
Motor I Imbalance
4
38
39
40
41
42
43
Phase U to Grnd
Phase V to Grnd
Phase W to Grnd
Phase UV Short
Phase VW Short
Phase UW Short
4
4
4
4
4
4
ACTION
Check remote wiring.
Monitor the incoming AC line for low voltage or
line power interruption.
FAULT
STATE
206
149
215
Monitor the incoming AC line for low voltage or
power interruption.
Monitor the AC line for high line voltage or transient conditions. Extend the decel time or check
RATED LINE VOLTAGE setting.
An excessive motor load exists. Reduce load so
drive output current does not exceed the MOTOR
NAMEPLATE AMPS setting.
149
215
150
205
1. Check operation of VFD cooling solenoid, VFD
isolation valves, and humidity sensor.
2. Check for proper temperature and flow rate of
coolant.
Output transistors have exceeded their
1. Check operation of VFD cooling solenoid, VFD
maximum operating temperature.
isolation valves, and humidity sensor.
coolant.
The drive output current has exceeded
Check programming. Check for excess load.
the hardware current limit.
Contact Carrier Service.
A current path to earth ground in excess Check the motor and external wiring to the drive
of 7% of drive rated amps has been
output terminals for a grounded condition.
detected at one or more of the drive output terminals.
The drive is not following a commanded 1. Verify input voltage is within drive specified
deceleration because it is attempting to
limits.
limit bus voltage.
2. Verify system ground impedance follows proper
grounding techniques.
Functions such as slip compensation or Remove excessive load conditions.
bus regulation have attempted to add an
output frequency adjustment greater
than that programmed in Overspeed
Limit (83).
An analog input is configured to fault on 1. Check parameters.
signal loss. A signal loss has occurred. 2. Check for broken/loose connections at inputs.
Configure with Anlg In 1, 2 Loss (324,
327).
Drive unsuccessfully attempted to reset 1. Correct the cause of the fault and manually
a fault.
clear.
2. Check parameters in VFD_CONF screen
The magnitude of motor current feed1. Verify connection of current feedback device
back was less than 5% Motor NP FLA
and motor terminals.
(42) for the time configured in Imbalance 2. If fault repeats, replace current feedback
Time (50). Detection of this fault is disdevices and/or power supply.
abled when Imbalance Time (50) is set to 3. Check VFD_CONF screen parameters.
the maximum value of 10.0 seconds.
The drive output current has exceeded
1. Check for excess load.
the software current.
1. Press ICVC RESET key to clear fault.
Phase current displayed in Imbalance
Display (221) > percentage set in Imbal- 2. Check motor leads and terminals.
ance Limit (49) for time set in Imbalance
Time (50).
A phase-to-ground fault has been
1. Check the wiring between the drive and motor.
detected between the drive and motor in 2. Check motor for grounded phase.
this phase.
3. Contact Carrier Service.
219
Internal electronic overload is set to trip
when the motor current equals 135% of
Motor NP FLA(42) for 1.5 seconds or
when PERCENT LOAD CURRENT is
sustained above 108%.
Base temperature exceeded limit.
Excessive current has been detected
between these two output terminals.
Fault Type indicates if the fault is:
1 — Auto-resettable
2 — Non-resettable
3 — User-configurable
4 — Normal Fault resettable using Carrier ICVC
“RESET” softkey
1. Check the motor and drive output terminal
wiring for a shorted condition.
2. Contact Carrier Service, replace drive.
217
219
246
220
204
206
206
206
206
246
225
220
220
NOTE: VFD Troubleshooting should only be performed by a
Reliance Certified LiquiFlo2 technician.
94
Table 16 — Fault Description and Corrective Actions (cont)
FAULT
CODE
48
FAULT
TYPE
DESCRIPTION
ACTION
Params Defaulted
4
The drive was commanded to write
default values to EEPROM.
63
Shear Pin
3
64
Drive OverLoad
4
70
HW Fault
4
Port 1-5 Net Loss
4
77
IR Volts Range
4
78
FluxAmpsRef Rang
4
79
Excessive Load
4
80
AutoTune Aborted
4
81- 85
Port 1-5 DPI Loss
4
87
Ixo Voltage Range
4
100
Parameter Chksum
2
101
102
103
104
UserSet1 Chksum
UserSet2 Chksum
UserSet3 Chksum
Pwr Brd Chksum1
2
2
2
4
Programmed Current Lmt Val (148) has
been exceeded.
Enabled/disable with Fault Config 1
(238).
Drive rating of 102% for 1 minute or
150% for 5 seconds has been
exceeded.
Inverter section of power module
detected an unexpected fault during
power stage diagnostics.
The network card connected to DPI port
stopped communicating.
The fault code indicates the offending
port number (71 = port 1, 72 = port 2,
etc.)
The drive autotuning default is calculated, and the value calculated for IR
Drop Volts is not in the range of acceptable values.
The value for flux amps determined by
the autotune procedure exceeds the
programmed Motor NP FLA (42).
Motor did not come up to speed in the
allotted time.
The autotune procedure was canceled
by the user.
DPI port stopped communicating.
An attached peripheral with control
capabilities via Local Mask (288) (or
OIM control) was removed.
The fault code indicates the offending
port number (81 = port 1, etc.)
Ixo voltage calculated from motor nameplate data is too high
The checksum read from the board does
not match the checksum calculated.
The checksum read from the user
set does not match the checksum
calculated.
105
Pwr Brd Chksum2
2
106
Incompat MCB-PB
2
107
Replaced MCB-PB
2
120
121
I/O Board Mismatch
I/O Board Comm
Loss
4
2
The checksum read from the EEPROM
does not match the checksum calculated from the EEPROM data.
Drive rating information stored on the
power board is incompatible with the
Main Control board.
Main Control board was replaced and
parameters were not programmed.
Incorrect I/O board identified.
Loss of communication to I/O board.
122
I/O Board Fail
4
Board failure.
200
Inverter Dsat
U, V, W
4
High current was detected in an IGBT.
71- 75
201
202
“RESET” softkey
1. Press ICVC RESET key or cycle power to the
VFD.
2. Program the drive parameters as needed.
Check MOTOR RATED LOAD AMPS setting in
VFD_CONF screen.
FAULT
STATE
206
206
Check RATED LINE AMPS and MOTOR RATED
LOAD AMPS in VFD_CONF screen.
246
Contact Carrier Service
206
1. Check communication board for proper
connection to external network.
2. Check external wiring to module on port.
Check ribbon cables, connectors, and pins.
3. Verify external network fault.
Check Motor Nameplate parameters in
VFD_CONF screen.
206
Check MOTOR NAMEPLATE AMPS in
VFD_CONF screen.
206
1. Check parameters in VFD_CONF screen.
Press ICVC RESET key to restart procedure.
203
1. If module was not intentionally disconnected,
check ribbon cables, connectors, and pins.
Replace wiring port expander, modules, Main
Control Board or complete drive as required.
2. Check OIM connection if used.
206
1. Press ICVC RESET key.
1. Press ICVC RESET key to restore defaults.
2. Cycle power to the VFD.
206
206
2. If problem persists, contact Carrier Service.
Load compatible version files into drive.
206
206
Program parameters into VFD_CONF screen.
206
Program parameters into VFD_CONF screen.
1. Press ICVC RESET key.
2. Check VFD board ribbon cables and connector pins.
1. Press ICVC RESET key, cycle power to the
VFD.
2. If fault repeats, replace I/O board.
1. Check for loose connection in IGBT wire
harness.
2. Check IGBTs.
3. Check precharge resistors and fuses.
4. Check precharge contactor.
206
206
206
206
206
206
206
201
95
FAULT
CODE
203
204
205
207
FAULT
TYPE
DESCRIPTION
ACTION
FAULT
STATE
246
Inverter OverCurrent
U, V, W
4
Check parameters in VFD_CONF screen.
Invtr Gate Kill
4
Inverter gate kill contact is open.
207
235
208
209
210
211
212
213
214
215
Rectifier Dsat
R, S, T
4
1. Check that condenser high pressure switch is
wired to the VFD gate kill contact.
2. Check that high pressure switch is closed.
1. Press RESET key on ICVC.
Rectifier Over Cur
R, S, T
4
Rectifier overcurrent
Check parameters in VFD_CONF screen.
241
Reactor Temp
Rctfr HW Unused
4
4
216
217
Rectifier Ground Fault
Rectifier Base Temp
4
4
218
Rectifier IGBT Temp
4
219
Rectifier IT Overload
4
220
Rectifier I2T Overload
4
221
Ride Thru Abort
4
222
High AC Line
4
223
Low DC Bus
4
224
Rctfr Over Volt
4
225
Input Amp Imbalance
4
226
Input Volt Imbalance
4
227
AC Line Lost
4
228
Line Frequency
4
229
Rectifier Checksum
4
230
Invtr HW Unk
4
Temperature switch in reactor opened.
Check for proper temperature and fan operation.
Rectifier portion of power structure hard- 1. Verify connection between rectifier control
ware reported unexpected fault
board and rectifier power board.
2. If fault persists, replace rectifier power board.
3. If fault still persists, replace rectifier inverter
control board.
Excessive ground current measured.
Check for grounded input wiring.
Excessive rectifier temperature
1. Check VFD cooling solenoid, VFD refrigerant
measured.
strainer, and VFD isolation valves.
coolant.
Excessive calculated IGBT temperature. 1. Check VFD cooling solenoid, VFD refrigerant
strainer, and VFD isolation valves.
coolant.
Short-term current rating of rectifier
Low input voltage can result in increased current
exceeded.
load. Provide proper input voltage to the drive.
Long-term current rating of rectifier
Low input voltage can result in increased current
exceeded.
load. Provide proper input voltage to the drive.
Input power loss timed out.
1. Verify input power and connections.
2. Check Line Sync board, connectors and pins.
3. Check AC Line I/O board, connectors, and
pins.
Input line voltage is too high.
Reduce input voltage to meet RATED LINE
VOLTAGE ±10%.
The bus voltage is too low.
1. Verify proper input voltage.
2. Check control center and input power fuses.
The bus voltage is too high.
Monitor the AC line for high line voltage or transient conditions. Extend the decel time.
Input phase current imbalance
1. Check for loose connection in input power
exceeded limits.
wiring.
2. Check precharge contactors.
Input voltage imbalance exceeded limits. 1. Check for problem in input power distribution.
2. Check input wiring connections.
Input power Lost
1. Verify proper input voltage.
2. Check line sync board and fuse.
3. Check AC line I/O board.
4. Verify connections between boards.
Line frequency not in the range of
Verify connection between AC Line Sync and AC
47-63 Hz.
Line I/O boards. Confirm that connectors are fully
engaged.
The checksum read from the board does 1. Check all power module connectors and cycle
power to the VFD.
3. Check parameters in VFD_CONF screen.
Inverter section of power structure hard- 1. Verify connection between inverter control
ware reported unexpected fault.
board and inverter power board.
2. If fault persists, replace inverter power board.
3. If fault still persists, replace inverter control
board.
“RESET” softkey
200
255
206
220
218
218
146
212
146
212
146
147
212
213
145
211
149
215
150
205
143
209
216
144
210
222
253
206
96
FAULT
CODE
231
Rctfr HW Unk
4
232
Rctfr Not OK
4
233
Precharge closed
4
234
Precharge open
4
235
Rctfr Pwr Board
4
236
Rctfr I/O Board
4
237
Not at Voltage
4
238
Rectfr Not Logged In
4
239
Power Phased ACB
4
FAULT
TYPE
DESCRIPTION
ACTION
Rectifier portion of power structure hard- 1. Verify connection between rectifier control
ware reported unexpected fault.
board and rectifier power board.
2. If fault persists, replace rectifier power board
3. If fault still persists, replace rectifier control
board.
A fault was detected in the rectifier other Look at rectifier parameter 243 to see fault code.
than one specifically decoded.
Contact Carrier.
Precharge was closed when it should be 1. Check AUX contacts on precharge. Check if
open.
precharge contactor is energized.
2. Check input bit 0 in rectifier parameter 216 to
view status of input.
3. Check wiring.
Precharge was open when it should be 1. Check AUX contacts on precharge. Check if
closed.
precharge contactor is de-energized.
2. Check input bit 0 in rectifier parameter 216 to
view status of input.
3. Check wiring.
Drive rating information stored on the
Load compatible version files into drive.
power board is incompatible with the
Main Control board.
2. If problem persists, contact Carrier Service.
Loss of communication to I/O board.
Board failure.
2. Check I/O board ribbon cables, connectors,
and pins.
3. If fault repeats, replace I/O board.
The rectifier did not regulate to the
1. Check all fuses and cabinet wiring.
desired bus voltage within the defined
2. Replace line synch board.
time.
3. Replace AC Line I/O board.
4. Replace rectifier control board and/or rectifier
power board.
Rectifier took too long to connect to
1. Check the cabling, connectors, and pins
inverter.
between the communications interface and the
two control boards.
2. Verify the DPI Data Rate (270) is set to 500K.
3. Connect one DPI device at a time to determine
if one of the DPI devices is causing the
problem.
4. Replace the communications interface.
5. Replace the rectifier control board.
6. Swap 80W power supplies to determine if the
fault follows the power supply. Replace the
power supply if needed.
Input Power is phased ACB rather than Switch two of the input power phases.
ABC.
“RESET” softkey
FAULT
STATE
206
200
206
206
206
206
149
215
206
226
97
2. If a green LED is on continuously, check the communication wiring. If a green LED is off, check the red LED operation. If the red LED is normal, check the SIO address
switches (Fig. 49 and 50). Confirm all SW1 SIO address
dip switches on the CCM are in the OFF position.
All system operating intelligence resides in the ICVC.
Some safety shutdown logic resides in the VFD Gateway in case communications are lost between the VFD
and ICVC. Outputs are controlled by the CCM and
VFD Gateway as well.
3. In the control center, a 3 KVA transformer steps down
line power to 115 V. This supplies power to the oil pump,
oil vaporizer heater, oil sump heater, and control power
transformers. Power is supplied to the ICVC and CCM
modules within the control center via the T1 24-VAC
transformer.
The control power transformers are located on the
power panel.
Transformer T1 supplies 24 V power to the ICVC and
CCM. Transformer T2 provides 20 V power to
optional DataPort™ or DataLINK™ modules.
Power is connected to Plug J1 on the ICVC and CCM
modules.
Control Modules — Turn controller power off before
servicing controls. This ensures safety and prevents damage to
the controller.
The ICVC and CCM modules perform continuous diagnostic evaluations of the hardware to determine its condition.
Proper operation of all modules is indicated by LEDs (lightemitting diodes) located on the circuit board of the ICVC and
CCM.
There is one green LED located on the CCM board, and one
red LED located on the ICVC and CCM boards.
RED LED (Labeled as STAT) — If the red LED:
• Blinks continuously at a 2-second interval — the module
is operating properly
• Is lit continuously — there is a problem that requires
replacing the module
• Is off continuously — the power should be checked
• Blinks 3 times per second — a software error has been
discovered and the module must be replaced
If there is no input power, check the CB2 control power
circuit breaker and control power transformer circuit breakers
(CB1A and CB1B). If the breakers are good, check for a shorted 24 vac secondary of the T1 transformer or, if power is
present to the module, replace the module.
GREEN LED (Labeled as COM) — These LEDs indicate
the communication status between different parts of the controller and the network modules and should blink continuously.
Chiller Control Module (CCM) (Fig. 50)
INPUTS — Each input channel has 2 or 3 terminals. Refer to
individual chiller wiring diagrams for the correct terminal
numbers for your application.
OUTPUTS — CCM terminals J11 and J12 are discrete (on/
off) outputs that switch 24 volts. The 4 to 20 mA output channel on terminals J8-1 and J8-2 is designed for non-grounded
controllers with a maximum input impedance of 500 ohms.
J8-3 and J8-4 are used with a 500-ohm resistor to control the
oil reclaim actuator.
Notes on Module Operation
1. The chiller operator monitors and modifies configurations in the microprocessor by using the 4 softkeys and
the ICVC. Communications between the ICVC and the
CCM is accomplished through the SIO (Sensor Input/
Output) bus, which is a phone cable. The communication
between the CCM and VFD is accomplished through a
3-wire SIO communication protocol cable.
GROUND
SIO COMMUNICATIONS (J7)
POWER AND CCN (J1)
RJ-14 SERVICE
CONNECTION (J8)
fa23-1640
Fig. 49 — Rear of ICVC (International Chiller Visual Controller)
98
Table 17A — Thermistor Temperature (F) vs Resistance/Voltage Drop
TEMPERATURE
(F)
–25
–24
–23
–22
–21
–20
–19
–18
–17
–16
–15
–14
–13
–12
–11
–10
–9
–8
–7
–6
–5
–4
–3
–2
–1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
PIC III
VOLTAGE
DROP (V)
4.700
4.690
4.680
4.670
4.659
4.648
4.637
4.625
4.613
4.601
4.588
4.576
4.562
4.549
4.535
4.521
4.507
4.492
4.477
4.461
4.446
4.429
4.413
4.396
4.379
4.361
4.344
4.325
4.307
4.288
4.269
4.249
4.229
4.209
4.188
4.167
4.145
4.123
4.101
4.079
4.056
4.033
4.009
3.985
3.960
3.936
3.911
3.886
3.861
3.835
3.808
3.782
3.755
3.727
3.700
3.672
3.644
3.617
3.588
3.559
3.530
3.501
3.471
3.442
3.412
3.382
3.353
3.322
3.291
3.260
3.229
3.198
3.167
3.135
3.104
3.074
3.042
3.010
2.978
2.946
2.914
2.882
2.850
2.819
2.788
2.756
2.724
2.692
2.660
2.628
2.596
RESISTANCE
(Ohms)
TEMPERATURE
(F)
97,706
94,549
91,474
88,480
85,568
82,737
79,988
77,320
74,734
72,229
69,806
67,465
65,205
63,027
60,930
58,915
56,981
55,129
53,358
51,669
50,062
48,536
47,007
45,528
44,098
42,715
41,380
40,089
38,843
37,639
36,476
35,354
34,270
33,224
32,214
31,239
30,298
29,389
28,511
27,663
26,844
26,052
25,285
24,544
23,826
23,130
22,455
21,800
21,163
20,556
19,967
19,396
18,843
18,307
17,787
17,284
16,797
16,325
15,868
15,426
14,997
14,582
14,181
13,791
13,415
13,050
12,696
12,353
12,021
11,699
11,386
11,082
10,787
10,500
10,221
9,949
9,689
9,436
9,190
8,951
8,719
8,494
8,275
8,062
7,855
7,655
7,460
7,271
7,088
6,909
6,736
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
PIC III
VOLTAGE
DROP (V)
2.565
2.533
2.503
2.472
2.440
2.409
2.378
2.347
2.317
2.287
2.256
2.227
2.197
2.167
2.137
2.108
2.079
2.050
2.021
1.993
1.965
1.937
1.909
1.881
1.854
1.827
1.800
1.773
1.747
1.721
1.695
1.670
1.644
1.619
1.595
1.570
1.546
1.523
1.499
1.476
1.453
1.430
1.408
1.386
1.364
1.343
1.321
1.300
1.279
1.259
1.239
1.219
1.200
1.180
1.161
1.143
1.124
1.106
1.088
1.070
1.053
1.036
1.019
1.002
0.986
0.969
0.953
0.938
0.922
0.907
0.893
0.878
0.864
0.849
0.835
0.821
0.808
0.795
0.782
0.769
0.756
0.744
0.731
0.719
0.707
0.696
0.684
0.673
0.662
0.651
0.640
99
RESISTANCE
(Ohms)
TEMPERATURE
(F)
6,568
6,405
6,246
6,092
5,942
5,796
5,655
5,517
5,382
5,252
5,124
5,000
4,880
4,764
4,650
4,539
4,432
4,327
4,225
4,125
4,028
3,934
3,843
3,753
3,667
3,582
3,500
3,420
3,342
3,266
3,192
3,120
3,049
2,981
2,914
2,849
2,786
2,724
2,663
2,605
2,547
2,492
2,437
2,384
2,332
2,282
2,232
2,184
2,137
2,092
2,047
2,003
1,961
1,920
1,879
1,840
1,801
1,764
1,727
1,691
1,656
1,622
1,589
1,556
1,524
1,493
1,463
1,433
1,404
1,376
1,348
1,321
1,295
1,269
1,244
1,219
1,195
1,172
1,149
1,126
1,104
1,083
1,062
1,041
1,021
1,002
983
964
945
928
910
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
PIC III
VOLTAGE
DROP (V)
0.630
0.619
0.609
0.599
0.589
0.579
0.570
0.561
0.551
0.542
0.533
0.524
0.516
0.508
0.499
0.491
0.484
0.476
0.468
0.460
0.453
0.445
0.438
0.431
0.424
0.418
0.411
0.404
0.398
0.392
0.385
0.379
0.373
0.367
0.361
0.356
0.350
0.344
0.339
0.333
0.328
0.323
0.318
0.313
0.308
0.304
0.299
0.294
0.290
0.285
0.281
0.277
0.272
0.268
0.264
0.260
0.256
0.252
0.248
0.245
0.241
0.237
0.234
0.230
0.227
0.224
0.220
0.217
0.214
0.211
0.208
0.205
0.203
0.198
0.195
0.192
0.190
0.187
0.184
0.182
0.179
0.176
0.174
0.172
0.169
0.167
0.164
0.162
0.160
0.158
0.155
0.153
RESISTANCE
(Ohms)
893
876
859
843
827
812
797
782
768
753
740
726
713
700
687
675
663
651
639
628
616
605
595
584
574
564
554
544
535
526
516
508
499
490
482
474
466
458
450
442
435
428
421
414
407
400
393
387
381
374
368
362
356
351
345
339
334
329
323
318
313
308
303
299
294
289
285
280
276
272
267
263
259
255
251
248
244
240
236
233
229
226
223
219
216
213
210
207
204
201
198
195
Table 17B — Thermistor Temperature (C) vs Resistance/Voltage Drop
TEMPERATURE
(C)
–33
–32
–31
–30
–29
–28
–27
–26
–25
–24
–23
–22
–21
–20
–19
–18
–17
–16
–15
–14
–13
–12
–11
–10
–9
–8
–7
–6
–5
–4
–3
–2
–1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
PIC III
VOLTAGE
DROP (V)
4.722
4.706
4.688
4.670
4.650
4.630
4.608
4.586
4.562
4.538
4.512
4.486
4.458
4.429
4.399
4.368
4.336
4.303
4.269
4.233
4.196
4.158
4.119
4.079
4.037
3.994
3.951
3.906
3.861
3.814
3.765
3.716
3.667
3.617
3.565
3.512
3.459
3.406
3.353
3.298
3.242
3.185
3.129
3.074
3.016
2.959
2.901
2.844
2.788
2.730
2.672
2.615
2.559
2.503
2.447
2.391
2.335
2.280
2.227
2.173
2.120
2.067
2.015
1.965
1.914
1.865
1.816
1.768
1.721
1.675
1.629
1.585
1.542
1.499
1.457
1.417
1.377
RESISTANCE
(Ohms)
TEMPERATURE
(C)
105 616
99 640
93 928
88 480
83 297
78 377
73 722
69 332
65 205
61 343
57 745
54 411
51 341
48 536
45 819
43 263
40 858
38 598
36 476
34 484
32 613
30 858
29 211
27 663
26 208
24 838
23 545
22 323
21 163
20 083
19 062
18 097
17 185
16 325
15 513
14 747
14 023
13 341
12 696
12 087
11 510
10 963
10 444
9 949
9 486
9 046
8 628
8 232
7 855
7 499
7 160
6 839
6 535
6 246
5 972
5 711
5 463
5 226
5 000
4 787
4 583
4 389
4 204
4 028
3 861
3 701
3 549
3 404
3 266
3 134
3 008
2 888
2 773
2 663
2 559
2 459
2 363
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
100
PIC III
VOLTAGE
DROP (V)
1.338
1.300
1.263
1.227
1.192
1.158
1.124
1.091
1.060
1.029
0.999
0.969
0.941
0.913
0.887
0.861
0.835
0.811
0.787
0.764
0.741
0.719
0.698
0.677
0.657
0.638
0.619
0.601
0.583
0.566
0.549
0.533
0.518
0.503
0.488
0.474
0.460
0.447
0.434
0.422
0.410
0.398
0.387
0.376
0.365
0.355
0.344
0.335
0.325
0.316
0.308
0.299
0.291
0.283
0.275
0.267
0.260
0.253
0.246
0.239
0.233
0.227
0.221
0.215
0.210
0.205
0.198
0.193
0.188
0.183
0.178
0.174
0.170
0.165
0.161
0.157
0.153
RESISTANCE
(Ohms)
2 272
2 184
2 101
2 021
1 944
1 871
1 801
1 734
1 670
1 609
1 550
1 493
1 439
1 387
1 337
1 290
1 244
1 200
1 158
1 117
1 079
1 041
1 006
971
938
906
876
846
818
791
765
740
715
692
670
648
628
608
588
570
552
535
518
502
487
472
458
444
431
418
405
393
382
371
360
349
339
330
320
311
302
294
286
278
270
262
255
248
242
235
229
223
217
211
205
200
195
J11
DISCRETE
OUTPUTS
SW1 SIO ADDRESS
DIPSWITCH
SET ALL TO “OFF”
J12
DISCRETE
OUTPUTS
J1
24 VAC
ANALOG OUT
J8
SIO
J7
SIO
J6
SW2 V/I
INPUT
CONFIGURATION
V/I INPUTS
J5
a23-1617
STAT
COMM
THERMISTORS
J4
DIFF PRESSURE
J3
PRESSURE
J2
Fig. 50 — Chiller Control Module (CCM)
Replacing Defective ICVC Modules — The mod-
ule replacement part number is printed on a small label on the
rear of the ICVC module. The chiller model and serial numbers are printed on the chiller nameplate located on the right
side of the control center. The proper software is factoryinstalled by Carrier in the replacement module. When ordering
a replacement international chiller visual controller (ICVC)
module, specify the complete replacement part number, full
chiller model number, and chiller serial number. The installer
must configure the new module to the original chiller data.
Follow the procedures described in the Software Configuration
section on page 59.
3.
Electrical shock can cause personal injury. Disconnect all
electrical power before servicing.
4.
5.
6.
INSTALLATION
1. Verify the existing ICVC module is defective by using the
procedure described in the Troubleshooting Guide section, page 78, and the Control Modules section, on this
page. Do not select the ATTACH TO NETWORK
DEVICE table if the ICVC indicates a CCN communication failure. Doing so will probably lock up the ICVC
because it will not be able to communicate with the CCN.
2. Any communication wires from other chillers or CCN
modules should be disconnected prior to installation of a
new module to prevent the new ICVC from uploading
incorrect run hours into memory. Data regarding the
ICVC configuration should have been recorded and
saved. This data must be reconfigured into the new
ICVC. If this data is not available, follow the procedures
7.
8.
101
described in the Software Configuration section. If the
module to be replaced is functional, configurations may
also be copied manually. The data sheets on pages CL-4
through CL-12 are provided for this purpose. Default
values are shown so that only deviations from these need
to be recorded.
If a CCN Building Supervisor or Service Tool is available, the module configuration should have already been
uploaded into memory. When the new module is
installed, the configuration can be downloaded from the
computer.
To install this module, record values for the TOTAL
COMPRESSOR STARTS, SERVICE ONTIME, and the
COMPRESSOR ONTIME from the MAINSTAT screen
on the ICVC.
Power off the controls.
Remove the old ICVC.
Install the new ICVC module. Turn the control power
back on.
The ICVC now automatically attaches to the local network device.
Set the current time and date in the SERVICE / TIME
AND DATE screen. Set the CCN Bus and Address in the
SERVICE / ICVC CONFIGURATION screen. Press the
alarm RESET soft key (from the default screen). Upload
via Service Tool or manually reenter all non-default configuration values. (Refer to pages CL-4 through CL-12).
If the correct VFD_CONF values are displayed when that
table is viewed, simply press EXIT then SAVE to reload
all of them. Using Service Tool or manually reenter
TOTAL COMPRESSOR STARTS, COMPRESSOR
ONTIME, and SERVICE ONTIME. If forced using
Service Tool, release the force on SERVICE ONTIME
after the desired value has been set. TOTAL COMPRESSOR STARTS and TOTAL COMPRESSOR ONTIME can
only be changed prior to the first completed start. If a start
is completed and the COMPRESSOR STARTS or COMPRESSOR ON TIME are both incorrect, the ICVC software must be downloaded again before these settings can
be changed.
9. Check and recalibrate pressure transducer readings (refer
to page 79). Check that the CURRENT TIME and DATE
in the TIME AND DATE screen are correct.
DPI Communications Interface Board Status LEDs — VFD
status can be determined from the status LEDs on the DPI
Communications Interface Board shown in Fig. 51. The DPI
Board is mounted on the front of the VFD power module in a
vertical orientation.
Table 19 — Gateway MS Status Indicator
STATE
Off
CAUSE
The Gateway is not
powered.
Flashing Recoverable Fault
Red
Condition
Solid
Red
Flashing
Green
Solid
Green
Gateway Status LEDs — The RS485 VFD Gateway
provides a communication link between the CCM and ICVC
SIO bus to the VFD Drive Peripheral Interface (DPI) board.
The SIO bus communicates with the Gateway through VFD
connector A32. See Fig. 52.
The Gateway has four status indicators on the top side of the
module.
DRIVE STATUS INDICATOR — The DRIVE status indicator is on the right side of the Gateway. See Table 18.
The module has failed
the hardware test.
The Gateway is operational. No I/O data is
being transferred.
The Gateway is operational and transferring
I/O data.
CORRECTIVE ACTION
• Securely connect the
Gateway to the drive using
the ribbon cable.
• Apply power to the drive.
Cycle power to the drive. If
cycling power does not correct the problem, the firmware may need to be flashed
into the module.
• Cycle power to the drive
• Replace the Gateway
Normal behavior during SIO
configuration initialization
process.
No action required.
NET A STATUS INDICATOR — The NET A status indicator is the third LED from the right of the Gateway. See
Table 20.
Table 20 — Gateway NET A Status Indicator
STATE
Off
CAUSE
The module is not powered or is not properly
connected to the
network.
First incoming network
command not yet
recognized.
Flashing Network has timed out.
Red
Solid
The Gateway has
Red
detected an error that
has made it incapable
of communication on
the network.
Flashing Online to network, but
Green
not producing or consuming I/O information.
Solid
The module is properly
Green
connected and communicating on the network.
Table 18 — Gateway DRIVE Status Indicator
STATE
Off
CAUSE
The Gateway is not
powered or is not connected properly to the
drive.
Flashing The Gateway is not
Red
receiving a ping message from the drive.
Solid
The drive has refused
Red
an I/O connection from
the Gateway.
CORRECTIVE ACTION
Gateway to the drive using
the DPI ribbon cable.
• Verify that cables are
securely connected.
• Cycle power to the drive.
IMPORTANT: Cycle power
after making the following
correction:
• Verify that all DPI cables
on the drive are securely
connected and not damaged. Replace cables if
necessary.
Orange The Gateway is con• Check wires leading to the
nected to a product that
A32 terminal block.
does not support Rock- • Check that A32 terminal
well Automation DPI
block is fully engaged.
communications.
Flashing The Gateway is estab- Normal behavior.
Green
lishing an I/O connection to the drive or the
I/O has been disabled.
Solid
The Gateway is propNo action required.
Green
erly connected and is
communicating with the
drive.
CORRECTIVE ACTION
Gateway ribbon cable to
the drive DPI board.
• Attach the RS485 cable in
Gateway to the connector.
Cycle power to the drive.
Check node address and
data rate switch positions on
the front of the Gateway.
Cycle power to the drive.
No action required. The LED
will turn solid green when
communication resumes.
No action required.
NET B STATUS INDICATOR — The NET B status indicator is the left LED on the Gateway. See Table 21.
Table 21 — Gateway NET B Status Indicator
STATE
Off
Solid or
Blinking
Green
MS STATUS INDICATOR — The MS status indicator is the
second LED from the right of the Gateway. See Table 19.
102
CAUSE
Gateway not receiving
data over the network.
Gateway is transmitting data.
CORRECTIVE ACTION
• Check wires leading to
A32 terminal block.
• Check that A32 terminal
block is fully engaged.
No action required.
DPI COMMUNICATIONS INTERFACE BOARD
INVERTER LED
RECTIFIER LED
a19-1634
INVERTER STATUS LIGHT
COLOR
Green
Yellow
Red
Red Inverter
Green Rectifier
STATE
Flashing
Steady
Flashing
Steady
Flashing
Steady
DESCRIPTION
Drive ready, but not running and no faults are present.
Drive running, no faults are present.
The drive is not ready. A VFD start inhibit is in effect. Normal condition when chiller not running because the ICVC has issued a stop command.
An alarm condition exits. Check VFD FAULT CODE in ICVC VFD_STAT screen.
A fault has occurred. Check VFD FAULT CODE in ICVC VFD_STAT screen.
A non-resettable fault has occurred. Check VFD FAULT CODE in ICVC VFD_STAT screen.
Steady
VFD Gate Kill circuit has opened because the compressor high pressure switch has opened.
RECTIFIER STATUS LIGHT
COLOR
Green
Yellow
Red
Red Inverter
Green Rectifier
STATE
Flashing
Steady
Flashing
Steady
Flashing
Steady
DESCRIPTION
Rectifier ready, but not running and no faults are present.
Rectifier running, no faults are present.
Rectifier is not ready. A VFD start inhibit is in effect. This is a normal state if the inverter is not running and/or the precharge contacts are open.
Rectifier alarm condition exits. Check VFD FAULT CODE in ICVC VFD_STAT screen.
Rectifier fault has occurred. Check (VFD FAULT CODE in ICVC VFD_STAT screen.
A non-resettable fault has occurred. Check VFD FAULT CODE in ICVC VFD_STAT screen.
Steady
VFD Gate Kill circuit has opened because the compressor high pressure switch has opened.
INVERTER AND RECTIFIER CONTROL BOARD FAILURE STATUS LIGHT PATTERNS
COLOR
Red/Green Alternating
Yellow/Green/Red
Repeating Pattern
DESCRIPTION
Control board application firmware may be corrupt. Call Carrier Service.
Control board RAM failure or control board firmware may be corrupt. Call Carrier Service.
Fig. 51 — DPI Communications Interface Board Status LEDs
Physical Data — Tables 22-28 and Fig. 53-57 provide
additional information on component weights, physical and
electrical data, and wiring schematics for the operator’s convenience during troubleshooting.
DPI RIBBON
CABLE CONNECTOR
NODE ADDRESS
TENS DIGIT = 0
(DO NOT
CHANGE)
Do not attempt to disconnect flanges while the machine is
under pressure. Failure to relieve pressure can result in personal injury or damage to the unit.
DATA
RATE = PGM
(DO NOT
CHANGE)
Before rigging the compressor, disconnect all wires entering the power panel.
A32
TERMINAL BLOCK
NODE ADDRESS
ONES DIGIT = 1
(DO NOT CHANGE)
NUMBER
1
2
3
4
STATUS
INDICATOR
DRIVE
MS
NET A
NET B
a23-1618
DESCRIPTION
DPI Connection Status
Module Status
Serial Communication Status
Serial Communication Traffic Status
NOTE: If all status indicators are off, the Gateway is not receiving power.
Fig. 52 — Gateway Status LEDs
103
Table 22 — 23XRV Heat Exchanger Weights
English
Dry Rigging Weight
(lb)*
CODE
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
55
56
57
Cooler
Only
Condenser
Only
4148
4330
4522
4419
4627
4845
5008
5178
5326
5463
5659
5830
5827
6053
6196
6370
6631
6795
3617
3818
4023
4529
4758
4992
4962
5155
5347
5525
5747
5967
6013
6206
6387
6708
6930
7138
Metric (SI)
Dry Rigging Weight
(kg)*
Machine Charge
Refrigerant
Weight (lb)
With
Without
Economizer Economizer
800
650
800
650
800
650
910
760
910
760
910
760
900
750
900
750
900
750
1015
865
1015
865
1015
865
1250
1100
1250
1100
1250
1100
1430
1280
1430
1280
1430
1280
Liquid Weight
(lb)
Cooler
Condenser
464
531
601
511
587
667
863
930
990
938
1014
1083
1101
1192
1248
1201
1304
1369
464
542
621
513
602
692
915
995
1074
998
1088
1179
1225
1304
1379
1339
1429
1514
Cooler
Only
Condenser
Only
1877
1959
2046
2000
2094
2193
2675
2758
2832
2882
2976
3061
3182
3294
3364
3429
3556
3636
1676
1769
1860
2089
2195
2299
2746
2839
2932
3001
3108
3214
3304
3397
3485
3620
3726
3826
Machine Charge
Refrigerant
Weight (kg)
With
Without
Economizer Economizer
363
295
363
295
363
295
413
345
413
345
413
345
408
340
408
340
408
340
460
392
460
392
460
392
567
499
567
499
567
499
649
581
649
581
649
581
Liquid Weight
(kg)
Cooler
Condenser
210
241
273
232
266
303
391
422
449
425
460
491
499
541
566
545
591
621
210
246
282
233
273
314
415
451
487
453
494
535
556
591
626
607
648
687
*Rigging weights are for standard tubes of standard wall thickness (Turbo-B3 and Spikefin 2, 0.025-in. [0.635 mm] wall).
NOTES:
1. Cooler includes the suction elbow and 1/2 the distribution piping weight.
2. Condenser includes float valve and sump, discharge elbow, and 1/2 the distribution piping weight.
3. For special tubes refer to the 23XRV Computer Selection Program.
4. All weights for standard 2 pass NIH (nozzle-in-head) design with victaulic grooves.
Table 23 — 23XRV Compressor Weights
ENGLISH
MOTOR
SIZE*
P,Q,R,S,T,
U,V
SI
Compressor
Weight†
(lb)
Stator
Weight
(lb)
Rotor
Weight
(lb)
Motor
Terminal
Cover
(lb)
4866
441
229
46
Compressor
Weight†
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Motor
Terminal
Cover
(kg)
2207
200
104
21
*Total compressor weight is the sum of the compressor components (compressor weight column), stator, and end bell weights.
†Compressor size number is the first digit of the motor code. See Fig. 1.
Table 24 — 23XRV Component Weights
COMPONENT
Isolation Valves
Suction Elbow
Discharge Pipe Assembly
Control Center
Vaporizer and Oil Sump
Economizer
FRAME 3 HEAT
EXCHANGER
lb
kg
70
32
179
81
747
339
1650
749
700
318
542
246
104
FRAME 4 HEAT
EXCHANGER
lb
kg
70
32
237
108
747
339
1650
749
700
318
542
246
FRAME 5 HEAT
EXCHANGER
lb
kg
115
52
232
105
747
339
1650
749
700
318
542
246
Table 25A — 23XRV Waterbox Cover Weights — English (lb)*
FRAMES 3, 4, AND 5
WATERBOX
DESCRIPTION
NIH,1 pass Cover 150 PSIG
NIH Plain End, 150 PSIG
MWB End Cover, 150 PSIG*
NIH Plain End, 300 PSIG
MWB End Cover, 300 PSIG*
COOLER
CONDENSER
Frame 3
Frame 4
Frame 5
Frame 3
Frame 4
Frame 5
Victaulic
Victaulic
Victaulic
Victaulic
Victaulic
Victaulic
Nozzles Flanged Nozzles Flanged Nozzles Flanged Nozzles Flanged Nozzles Flanged Nozzles Flanged
282
318
148
185
168
229
282
318
148
185
168
229
287
340
202
256
222
276
287
340
191
245
224
298
294
310
472
488
617
634
294
310
503
519
628
655
243
243
138
138
154
154
225
225
138
138
154
154
243/315 243/315 138/314 138/314 154/390 154/390 225/234 225/234 138/314 138/314 154/390 154/390
411
486
633
709
764
840
411
486
633
709
764
840
411
518
626
733
760
867
411
578
622
729
727
878
433
468
660
694
795
830
433
468
655
689
785
838
291
291
522
522
658
658
270
270
522
522
658
658
445/619 445/619 522/522 522/522 658/658 658/658 359/474 359/474 522/522 522/522 658/658 658/658
LEGEND
MWB — Marine Waterbox
NIH
— Nozzle-In-Head
*Rows with two entries list nozzle end weight/return end weights.
NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included in the heat exchanger weights shown in Table 22.
Table 25B — 23XRV Waterbox Cover Weights — SI (kg)*
FRAMES 3, 4, AND 5
WATERBOX
DESCRIPTION
NIH,1 pass Cover 1034 kPa
NIH Plain End, 1034 kPa
MWB End Cover, 1034 kPa
NIH Plain End, 2068 kPa
MWB End Cover, 2068 kPa
Frame 3
Victaulic Flanged
Nozzles
128
144
130
154
133
141
110
110
110/143 110/143
186
220
186
235
196
212
132
132
202/281 202/281
COOLER
Frame 4
Victaulic Flanged
Nozzles
67
84
92
116
214
221
63
63
63/142
63/142
287
322
284
332
299
315
237
237
237/237 237/237
Frame 5
Victaulic Flanged
Nozzles
76
104
101
125
280
288
70
70
70/177
70/177
347
381
344
393
361
376
298
298
298/298 298/298
Frame 3
Victaulic Flanged
Nozzles
128
144
130
154
133
141
102
102
102/106 102/106
186
220
186
235
196
212
122
122
163/215 163/215
CONDENSER
Frame 4
Victaulic Flanged
Nozzles
67
84
87
111
228
235
63
63
63/142
63/142
287
322
282
331
297
313
237
237
237/237 237/237
LEGEND
MWB — Marine Waterbox
NIH
— Nozzle-In-Head
*Rows with two entries list nozzle end weight/return end weights.
NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included in the heat exchanger weights shown in Table 22.
Table 26 — Optional Storage Tank and/or Pumpout System Physical Data
UNIT
SIZE
28
52
TANK OUTSIDE
DIAMETER
in.
24.00
27.25
DRY WEIGHT
mm
610
692
lb
2334
3414
kg
1059
1549
MAXIMUM REFRIGERANT CAPACITY
ASHRAE/ANSI 15
VL-1963
HFC-134a
HFC-134a
lb
kg
lb
kg
1860
844
1716
778
3563
1616
3286
1491
LEGEND
ANSI
— American National Standards Institute
ARI
— Air Conditioning and Refrigeration Institute
ASHRAE — American Society of Heating, Refrigeration, and Air
Conditioning Engineers
NOTES:
1. ANSI/ASHRAE 15 — Safety Code for Mechanical Refrigeration
2. Dry weights include the pumpout condensing unit weight of 164 lb (75 kg).
Table 27 — Optional Storage Tank and/or
Pumpout System Electrical Data
VOLTS-PH-HZ
208/230-3-50/60
460-3-60
400-3-50
LRA
RLA
MAX RLA
15.8
7.8
7.8
LEGEND
— Locked Rotor Amps
— Rated Load Amps
105
LRA
105.0
52.0
52.0
Frame 5
Victaulic Flanged
Nozzles
76
104
102
135
285
297
70
70
70/177
70/177
346
381
330
398
356
380
298
298
298/298 298/298
Table 28 — 23XRV Compressor Torque Specification Chart
PART NO.
DESCRIPTION
LOCATION/USAGE
Hermetic Term, Outlet Casing Sub-ASS’Y
Motor Side Seal Installation
8TR0116
M5 X 0.8 X 30LG SHCS GR 12.9
Inlet Seal Installation
8TR0117
M5 X 0.8 X 60LG SHCS GR 12.9
Inlet Seal Installation
8TR0303
M10 X 1.5 X 40LG SHCS GR 12.9
Bearing Cover Installation
8TR0304
M20 X 1.0 X 120LG SHCS GR 12.9
Outlet Casing Process Bolts
Motor Terminal Cover Install
8TR0120
M12 X 1.75 X 50LG SHCS GR 12.9
and Lube Block
Motor
Housing and
8TR0122
M20 X 2.5 X 80LG SHCS GR 12.9
Bearing Cover Installation
8TR0381
M20 X 2.5 X 310LG HHCS GR 12.9
Discharge Flange
8TC0089C
Set Screw M10 X 1.5 X 30
Motor Stator Sub-Assembly
1/ ″ NPTF
Bearing Cover Lube Plug
8TC0290C
4
8TQ0189
M6 X 1.0 X 25LG SHCS GR 12.9
Rotor Caps & Male Axial Seal
3/ ″ SAE (9/
8TC0107C
Plug Installation
8
16 Thread)
3/ ″ SAE (9/
8TR0106
Plug Installation
8
16 Thread)
3/ ″ SAE (11/
8TC0109C
Rotor Housing
4
16 Thread)
7/ ″ SAE (13/
Motor Housing Air Gap Check
8TR0128
8
16 Thread)
HY85AA062
13/16″, Terminal Pin Body
Motor Installation
5/ ″, Term Nut, Mtr Lead, Term Nut
HY85AA062
Motor Installation
8
8TR0121
M16 X 2 X 70LG HHCS GR 10.9
Motor Rotor (Special)
Lube Cover Plate Installation
8TC1044
M12 X 1.75 X 30LG SHCS GR 12.9
Valve Pad Installation
5/ ″ — 11UNC X 1.88″ LG HHCS GR 8
Economizer Cover
8TR0238
8
1/ -27 NPT (Brass) Orifice
8TR0357
Lube Block & Bearing Cover Plate
8
3/ ″ SAE (9/
Lube Block
8TR0358
8
16 Thread) Choke Orifice
7/ ″ 9 UNC X 2″ LG HHCS GR 8
8TR0363
Suction & Discharge Covers
8
8TR0115
GR
HHCS
LG
SHCS
UNC
M5 X 0.8 X 16LG SHCS GR 12.9
—
—
—
—
—
LEGEND
Grade
Hex Head Cap Screw
Long
Socket Head Cap Screw
Unified Coarse Thread
106
TORQUE
lb-ft
Nm
5-
7
7-
9
5- 7
5- 7
50- 55
430-450
7- 9
7- 9
68- 75
583-610
90- 95
122-129
430-450
583-610
430-450
30- 35
20- 25
7- 9
17- 19
17- 19
83- 92
92-103
45- 55
40- 45
17- 22
583-610
41- 47
27- 34
9- 12
23- 26
23- 26
112-125
125-140
61- 75
54- 61
23- 30
87- 93
118-126
185-195
4- 6
17- 19
430-450
251-264
5- 8
23- 26
583-610
a23-1588
Fig. 53 — 23XRV Controls Schematic
107
a23-1589
Fig. 53 — 23XRV Controls Schematic (cont)
108
a23-1641
109
Fig. 53 — 23XRV Controls Schematic (cont)
NOTES:
1. This feature is standard in the 23XR controls, but requires
a controller with a non-grounded 4-20mA or 1-5Vdc output
signal, not by Carrier.
an external controller with a non-grounded 4-20mA output
signal, not by Carrier.
a sensor package option, by Carrier. (Item #3 see option
listing.)
4. Pins shown for reference only. Actual pin layout not shown.
5. This feature is standard in the 23XR controls. Controllers
monitoring this signal must have a non-grounded input with
a maximum impedance of 500 ohms.
110
120A
118
116
114
K1A
TS1
20A
600V
2
T1
T2
T3
A2
L1
L2
L3
A1
15 3
14
13
154
PRECHARGE
CONTACTORS
1 32
PRECHARGE
RESISTORS
10 , 600W
137A,B
FU4
139
R4
12 8
FU7
127
13 6
4x 140J
2V
FU5
FU6
150A
600V
129
119A
117
115
IND1
INPUT INDUCTOR
MAIN
CIRCUIT BREAKER
CB1
GND
13 8
20A
600V
1uF
113
46uF ea
100k , 50W
FILTER CAP ASSY
a23-1633
1
4
R
R5
131
FU8
130A
7
1
L1
155
A1
L3
L2
L1
13
5
L2
T1
14
A2
T3
T2
8
2
S
9
3
T
K1B
15 6
6
L3
140
135
20A
600V
1
M3
M2
R6
134
FU9
2
1
2
1
FU3
FU2
FU1
152
157
A1
L3
L2
L1
13
124
123
126
125
1A/600V
CLASS 'CC'
133
112
110
108
151
A2
T3
T2
T1
14
111
109
107
106
2
105
T2
L2
ST
103
T1
L1
104
CONTROL BREAKER
(2 POLE, 15A)
CB2
AC INPUT
FIELD WIRING
158
K1C
141
(
M4
2
1
TB3
4
3
2
1
122
121
)
X2
X1
145
MECHANICAL
JUMPER
H1-H4: 380-415VAC
H1-H5: 440-480VAC
*T1 INPUT (50/60Hz)
H*
H1
(3.0kVA, 120V, 25A)
CONTROL POWER
TRANSFORMER
T1
CLASS 'CC'
15A
5A
FU10
FU11A
FU11B
0.5A
P1-10
F1
PILOT
RELAY
P1-9
P1-12
+
(OPTIONAL)
METERS W/SWITCH
VM1
VOLTMETER
A2 LINE SYNC PCB
P1-14
P1-8
P1-7
P1-13
SW1
P2-3
I/O_ DGND
+5V_I/O
L2
B2 B1 A2 A1
L1
P2-18
P2-17
P2-14
P2-13
+
AMMETER
COIL_RETURN
+24V_COIL
AM1
OVER_TEMP_2
OVER_TEMP_1
14
13
12
11
8
9
10
+12VDC_I/O
7
6
5
4
I/O_AGND
RECT_AC_LINE
I/O_AGND
-12VDC_I/O
3
2
1
P1
P2-8
L3
/BC>CA
/AB>BC
/CA>AB
150C
190
P2-9
P2-10
P2-7
P2-6
P2-5
P2-4
P2-1
P2-2
P1-5
101C
P1-3
SIGNAL
CONDITIONING
AND ISOLATION
P1-11
150D
101D
P1-1
101A
Fig. 54 — 23XRV VFD Schematic
120V
SWITCHED
120V_N
142
150F
102C
CLASS 'CC'
102B 15A
102A
187
TB1
A12
AC LINE I/O
LOGIC COM
LOGIC IN 1
LOGIC IN 2
LOGIC IN 3
LOGIC IN 4
DO NC5
DO COM5
DO NO5
DO NC6
DO COM6
DO NO6
AO I1AO I1+
EXV C2EXV C2+
DO NC1
DO COM1
DO NO1
DO NC2
DO COM2
DO NO2
DO NC3
DO COM3
DO NO3
DO NC4
DO COM4
DO NO4
AO V1AO V1+
EXT NTC
EXT COM
TB1
+24V
LOGIC COM
24V COM
DI1
DI2
DI3
DI4
DI5
DI6
DO NC1
DO COM1
DO NO1
DO NC2
DO COM2
DO NO2
AI I1AI I1+
AI I2AI I2+
-10V
+10V
AI V1AI V1+
AI V2AI V2+
Vref COM
AO V1AO V1+
AO I1AO I1+
A1 VFD POWER MODULE
L1
L2
L3
188
186
185
184
183
STANDARD I/O
A22
150A
101B
150B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
U
V
W
169
T3
6
GND
M1
MOTOR
155
156
154
EXTERNAL- REF. ONLY
T1
T2
COM
4
SHIELD
B
5
A
2
TERM
174
173
17 5
17 7
3
1
170
1
2
3
4
5
6
7
8
9
10
15
16
17
18
19
20
21
22
23
24
O I L I NT / L OC K
TB2
3
2
1
GND
POS
COM
NEG
CN3
EVAP PUMP
EVAP PUMP
COND PUMP
COND PUMP
TOWER FAN LOW
TOWER FAN LOW
TOWER FAN HIGH
TOWER FAN HIGH
TRIP ALARM
TRIP ALARM
RED
BLK
WHT
HIGH PRESS SW
HIGH PRESS SW
4-20mA PRESS REF4-20mA PRESS REF+
SPARE SAFETY
SPARE SAFETY
ICE BUILD
ICE BUILD
REMOTE START
REMOTE START
TB1
CN2
OIL INT/LOCK
PE
LL2
L L1
CN1A
SH2
SH 1
CN1B
NOTE: MOTOR OVERLOAD IS
FACTORY PRE-SET.
DO NOT ADJUST.
159
160
161
162
163
164
165
166
167
168
FOR TECHNICAL SUPPORT CALL 1-800-726-8112
A34
NTC
A32
RS485
2
1
TB1
GATE-KILL
A33
179
180
171
172
2
1
2
1
a23-1585
Fig. 55 — Typical Field Wiring Schematic
111
a23-1586
Fig. 55 — Typical Field Wiring Schematic (cont)
112
fig55-notes-chart
Fig. 55 — Typical Field Wiring Schematic (cont)
113
NOTES FOR FIG. 55
GENERAL
1.0
Variable frequency drive (VFD) shall be designed and
manufactured in accordance with Carrier engineering
requirements.
1.1
All field-supplied conductors, devices and the fieldinstallation wiring, termination of conductors and devices,
must be in compliance with all applicable codes and job
specifications.
1.2
The routing of field-installed conduit and conductors and the
location of field-installed devices, must not interfere with
equipment access or the reading, adjusting or servicing of
any component.
1.3
Equipment installation and all starting and control devices,
must comply with details in equipment submittal drawings
and literature.
1.4
Contacts and switches are shown in the position they would
assume with the circuit de-energized and the chiller
shutdown.
1.5
3.1
3.2
3.3
Ice build start/terminate device contacts, remote start/stop
device contacts and spare safety device contacts, (devices
not supplied by Carrier), must have 24 VAC rating. Max current is 60 mA, nominal current is 10 mA. Switches with gold
plated bifurcated contacts are recommended.
Remove jumper wire between TB1-19 and TB1-20 before
connecting auxiliary safeties between these terminals.
Each integrated contact output can control loads (VA) for
evaporator pump, condenser pump, tower fan low, tower fan
high, and alarm annunciator devices rated 5 amps at
115 VAC and up to 3 amps at 277 VAC.
Control wiring required for Carrier to start pumps and tower fan
motors and establish flows must be provided to assure machine
protection. If primary pump, tower fan and flow control is by other
means, also provide a parallel means for control by Carrier. Failure
to do so could result in machine freeze-up or over-pressure.
Do not use aluminum conductors. Contractor/installer assumes all
liability resulting from the use of aluminum conductors within the
VFD enclosure.
3.4
3.5
POWER WIRING TO VFD
2.0
Provide a means of disconnecting branch feeder power to
VFD. Provide short circuit protection and interrupt capacity
for branch feeder in compliance with all applicable codes.
2.1
If metal conduit is used for the power wires, the last 4 feet or
greater should be flexible to avoid transmitting unit vibration
into the power lines and to aid in serviceability.
2.2
Line side power conductor rating must meet VFD nameplate
voltage and chiller minimum circuit ampacity.
2.3
Lug adapters may be required if installation conditions
dictate that conductors be sized beyond the minimum
ampacity required. Circuit breaker lugs will accommodate
the quantity (#) and size cables (per phase) as shown in
Table 29.
2.4
Compressor motor and controls must be grounded by using
equipment grounding lug provided inside unit mounted VFD
enclosure.
CONTROL WIRING
3.0
Field-supplied control conductors to be at least 18 AWG or
larger.
3.6
Do not use control transformers in the control center as the
power source for external or field-supplied contactor coils,
actuator motors or any other loads.
Do not route control wiring carrying 30 V or less within a
conduit or tray which has wires carrying 50 V or higher or
along side wires carrying 50 V or higher.
Spare 4-20 mA output signal is designed for controllers with
a non-grounded 4-20 mA input signal and a maximum input
impedance of 500 ohms.
Flow devices to confirm evaporator or condenser pump flow
are not required. However; if flow devices are used, wire as
shown on drawing 23XRC1-1 (J3 lower). Remove jumper
installed at these terminals and wire in a 4.3 K resistor in its
place.
CCM
J3 (LOWER)
a23-1587
The flow device and resistor must be installed in parallel at
these terminals such that the resistor provides a signal when
the flow device is open.
Table 29 — Lug Capacity
STANDARD 65K AIC LUG CAPACITY OPTIONAL 100K AIC LUG CAPACITY
VFD
(PER PHASE)
(PER PHASE)
MAX. INPUT
AMPS.
No. Conductors Conductor Range No. Conductors Conductor Range
225A
3
3/0 — 500MCM
2
3/0 — 250MCM
338A
3
3/0 — 500MCM
2
400 — 500MCM
440A
3
3/0 — 500MCM
2
400 — 500MCM
520A
3
3/0 — 500MCM
3
3/0 — 400MCM
608A
3
3/0 — 500MCM
3
3/0 — 400MCM
NOTE: If larger lugs are required, they can be purchased from the manufacturer of the circuit
breaker (Cutler-Hammer or Square D).
114
1
2
3
a23-1593
115
—
—
—
Field Wiring
DRAIN WIRE
BLACK
WHITE
RED
DRAIN WIRE
NOTE: Field-supplied terminal strip must be located in control panel.
3
BLACK
WHITE
RED
2
Fig. 56 — CCN Communication Wiring For Multiple Chillers (Typical)
GROUND
LEGEND
Carrier Comfort Network® (CCN) Interface
Circuit Breakers
Chiller Control Module (CCM)
Factory Wiring
BLACK
RED
WHITE
1
BLACK
WHITE
RED
DRAIN WIRE
BLACK
WHITE
RED
DRAIN WIRE
a23-1597
116
Fig. 57 — Lead/Lag Control Wiring
a23-1598
117
Fig. 57 — Lead/Lag Control Wiring (cont)
APPENDIX A — ICVC PARAMETER INDEX
PARAMETER
1st Current Alarm State
20mA Demand Limit Opt
(Demand Limit & KW Ramp)
2nd Current Alarm State
3rd Current Alarm State
4th Current Alarm State
5th Current Alarm State
Active Delta P
Active Delta T
Active Demand Limit
Actual VFD Speed
Actual VFD Speed
Actual VFD Speed
Actual VFD Speed (At Last Fault)
Address #
Alarm Configuration
ALARM HISTORY
Alarm Relay Test
Alarm Routing (Alarm Configuration)
ALERT HISTORY
Amps or KW Load Ramp %/Min
(Demand Limit and KW Ramp)
Amps/KW Ramp
Auto Chilled Liq Reset
Auto Demand Limit Input
Auto Restart Option
Average Line Current
Average Line Voltage
Average Load Current
Base Demand Limit
Baud Rate
Broadcast Option (CCN Occupancy Config)
Bus #
Calc Evap Sat Temp
Calc Evap Sat Temp
Cap Delta (Capacity Control)
Capacity Control
Capacity Control
CCN
CCN Mode ?
CCN Occupancy Config
CCN Time Schedule
CCN Time Schedule(OCCPC03S)
Chill Liq Pulldown/Min
Chilled Liquid Deadband
Chilled Liquid Delta T
Chilled Liquid Flow
Chilled Liquid Flow
Chilled Liquid Pump
Chilled Liquid Pump
Chilled Liquid Temp
Chilled Medium
Chilled Water Temp
Chiller Fault State (At Last Fault)
Chiller Start/Stop
CHL Delta T->Full Reset
(Temperature Reset Type 3)
CHL Delta T->No Reset
(Temperature Reset Type 3))
CHW Setpt Reset Value
Commanded State
MENU SOFTKEY
TABLE
SERVICE
SCREEN NAME
CUR_ALRM
CONFIGURABLE
SERVICE
EQUIPMENT SERVICE
RAMP_DEM
X
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
X
CUR_ALRM
CUR_ALRM
CUR_ALRM
CUR_ALRM
HEAT_EX
HEAT_EX
MAINSTAT
CAPACITY
COMPRESS
POWER
VFD_HIST
ICVC CONFIGURATION
NET_OPT
CONTROL TEST
DISCRETE OUTPUTS
NET_OPT
X
X
SERVICE
EQUIPMENT SERVICE
RAMP_DEM
X
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
STATUS
STATUS
SETPOINT
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
CAPACITY
STATUS
SERVICE
SCHEDULE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
STATUS
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
CONTROL TEST
CONTROL TEST
EQUIPMENT SERVICE
MAINSTAT
MAINSTAT
OPTIONS
POWER
POWER
POWER
SETPOINT
ICVC CONFIGURATION
NET_OPT
ICVC CONFIGURATION
HEAT_EX
OVERRIDE
CAPACITY
CAPACITY
SETUP2
DEFAULT SCREEN
ICVC_PWD
NET_OPT
OCCP03S
OCCDEFCS
HEAT_EX
SETUP1
HEAT_EX
PRESSURE TRANSDUCERS
PUMPS
HEAT_EX
PUMPS
STARTUP
PUMPS
STARTUP
MAINSTAT
SETUP1
WSMCHLRE
VFD_HIST
MAINSTAT
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
X
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
X
SERVICE
SERVICE
SERVICE
EQUIPMENT SERVICE
WSMCHLRE
WSMCHLRE
LEADLAG
X
118
APPENDIX A — ICVC PARAMETER INDEX (cont)
PARAMETER
Comp Discharge Temp
Comp Discharge Temp
Comp Discharge Temp
Comp Maximum Speed
Comp Maximum Speed
Comp Maximum Speed
Comp Maximum Speed
Comp Minimum Speed
Comp Minimum Speed
Comp Minimum Speed
Comp Minimum Speed
Comp Motor Frequency (At Last Fault)
Comp Motor RPM
Comp Motor RPM
Comp Motor RPM
Comp Motor RPM
Comp Motor RPM (At Last Fault)
Compressor Ontime
Compressor Ontime
Cond Approach Alert
Cond Press Override
Cond Press Override
Condenser Approach
Condenser High Pressure
Condenser Liquid Pump
Condenser Pressure
Condenser Pressure
Condenser Pressure
Condenser Temperature
CONSM01E
Control Mode
Control Point
Control Point Error (Capacity Control)
Control Point (Capacity Control)
CONTROL TEST
Current CHW Setpoint
Current Date
Current Mode (Lead/Lag)
Current Time
MENU SOFTKEY
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
STATUS
SERVICE
SERVICE
STATUS
STATUS
STATUS
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
STATUS
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SETPOINT
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
TABLE
EQUIPMENT SERVICE
CONTROL TEST
EQUIPMENT SERVICE
CONTROL TEST
VFD CONFIG DATA
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
CONTROL TEST
CONTROL TEST
CONTROL TEST
EQUIPMENT SERVICE
119
SCREEN NAME
OVERRIDE
SETUP1
COMPRESS
OVERRIDE
THERMISTORS
COMPRESS
POWER
STARTUP
CAPACITY
CAPACITY
COMPRESS
POWER
STARTUP
POWER
CAPACITY
COMPRESS
STARTUP
VFD_HIST
CAPACITY
COMPRESS
POWER
STARTUP
VFD_HIST
OVERRIDE
SETUP1
COMPRESS
OVERRIDE
THERMISTORS
VFD_CONF
DEFAULT SCREEN
MAINSTAT
SETUP1
SETUP1
OVERRIDE
SETUP1
HEAT_EX
SETUP1
VFD_STAT
HEAT_EX
PUMPS
PUMPS
STARTUP
PUMPS
STARTUP
HEAT_EX
OVERRIDE
HEAT_EX
OVERRIDE
DEFAULT SCREEN
CONSM01E
MAINSTAT
MAINSTAT
CAPACITY
SETPOINT
TEMP_CTL
CAPACITY
WSMCHLRE
TIME AND DATE
LL_MAINT
TIME AND DATE
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
PARAMETER
MENU SOFTKEY
Date
SERVICE
Day of Week
SERVICE
Daylight Savings
SERVICE
DC Bus Voltage
STATUS
STATUS
DC Bus Voltage Reference (At Last Fault)
SERVICE
DC Bus Voltage (At Last Fault)
SERVICE
Decrease Ramp Time
SERVICE
Degrees Reset at 20 mA
SERVICE
Degrees Reset (Temperature Reset Type 2)
SERVICE
Degrees Reset (Temperature Reset Type 3)
SERVICE
Delta P at 0% (4 mA) (Head Pressure Reference)
SERVICE
Delta P at 100% (20 mA)
SERVICE
(Head Pressure Reference)
Demand Kilowatts
STATUS
Demand Limit and KW Ramp
SERVICE
Demand Limit At 20 mA (Demand Limit & KW Ramp)
SERVICE
Demand Limit Decrease (Loadshed Function)
SERVICE
Demand Limit Inhibit
SERVICE
SERVICE
Demand Limit Source
SERVICE
SERVICE
Disable Service Password
STATUS
Discharge Pressure
SERVICE
Discharge Superheat
STATUS
Discharge Superheat
SERVICE
Discrete Outputs Control Test
SERVICE
ECL Control Option (Control Point)
SERVICE
ECL Delta T (Capacity Control)
SERVICE
ECL Reset (Capacity Control)
SERVICE
ECL Setpoint (Base Demand Limit Control Point)
SETPOINT
Emergency Stop
STATUS
Enable Reset Type (Temperature Reset)
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
Equipment Status
SERVICE
Evap Approach Alert
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
Evap Sat Override Temp
SERVICE
Evaporator Approach
STATUS
Evaporator Pressure
STATUS
Evaporator Pressure
SERVICE
Evaporator Temperature
SERVICE
Flux Current
STATUS
Flux Current (At Last Fault)
SERVICE
Frequency Fault
STATUS
Full Load Point (T2,P2)(Hot Gas Bypass)
SERVICE
Ground Fault
STATUS
STATUS
Ground Fault Current (At Last Fault)
SERVICE
Group Number (Loadshed Function)
SERVICE
TABLE
CONFIGURABLE
X
X
VFD CONFIG DATA
SCREEN NAME
TIME AND DATE
TIME AND DATE
BRODEF
POWER
POWER
VFD_HIST
VFD_HIST
VFD_CONF
EQUIPMENT SERVICE
TEMP_CTL
X
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
TEMP_CTL
TEMP_CTL
OPTIONS
X
X
X
EQUIPMENT SERVICE
OPTIONS
X
EQUIPMENT SERVICE
EQUIPMENT SERVICE
POWER
RAMP_DEM
RAMP_DEM
NET_OPT
CAPACITY
EQUIPMENT SERVICE
RAMP_DEM
X
X
X
X
EQUIPMENT SERVICE
RAMP_DEM
X
EQUIPMENT SERVICE
RAMP_DEM
ICVC_PWD
COMPRESS
OVERRIDE
CONTROL TEST
TEMP_CTL
CAPACITY
CAPACITY
SETPOINT
MAINSTAT
TEMP_CTL
CAPACITY
DEFAULT SCREEN
HEAT_EX
THERMISTORS
HEAT_EX
THERMISTORS
DEFAULT SCREEN
WSMCHLRE
SETUP1
SETUP1
HEAT_EX
THERMISTORS
SETUP1
OVERRIDE
HEAT_EX
HEAT_EX
DEFAULT SCREEN
SETUP1
POWER
VFD_HIST
VFD_STAT
OPTIONS
VFD_STAT
POWER
VFD_HIST
NET_OPT
X
X
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
EQUIPMENT SERVICE
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
120
X
X
X
X
X
X
X
X
X
PARAMETER
Head Pressure Output Control Test
HGBP Deadband
HGBP Delta P1(Min Load Point)
HGBP Delta P2(Full Load Point)
HGBP Delta T
HGBP Delta T1(Min Load Point)
HGBP Delta T2(Full Load Point)
HGBP On Delta T
HGBP Off Delta T
High DC Bus Voltage
High Line Voltage
Holiday
HOLIDAYS
Hot Gas Bypass
HGBP Option
Hot Gas Bypass Relay Test
Ice Build Contact
Ice Build Control
Ice Build Option (Ice Build Control)
Ice Build Recycle
Ice Build Setpoint
Ice Build Time Schedule
Ice Build Time Schedule(OCCPC02S)
ICVC Address #
ICVC Baud Rate
ICVC Bus #
ICVC CONFIGURATION
ICVC LID Language
ICVC Model #
ICVC Reference #
ICVC Serial #
ICVC Software Part #
ICVC US IMP/Metric
Increase Ramp Time
Inverter Overcurrent
Inverter Overload
Inverter Overtemp
Inverter Power Fault
Inverter Temperature (At Last Fault)
LAG % Capacity
LAG Address
LAG CHILLER: Mode
LAG START Time
LAG START Timer
LAG STOP Time
LAG STOP Timer
LCL Reset (Capacity Control)
LCL Setpoint (Base Demand Limit Control Point)
LEAD CHILLER in Control
Lead Lag Control
Lead Lag Control
LEAD/LAG: Configuration
LEAD/LAG: Configuration
MENU SOFTKEY
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SETPOINT
SERVICE
SCHEDULE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SETPOINT
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
TABLE
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
VFD CONFIG DATA
VFD CONFIG DATA
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
121
SCREEN NAME
CONTROL TEST
HEAD PRESSURE OUTPUT
HEAT_EX
OPTIONS
OPTIONS
OPTIONS
OPTIONS
HEAT_EX
OPTIONS
OPTIONS
OPTIONS
OPTIONS
VFD_STAT
VFD_STAT
TIME AND DATE
HOLIDAYS
OPTIONS
OPTIONS
HEAT_EX
DISCRETE OUTPUTS
POWER
MAINSTAT
OPTIONS
OPTIONS
OPTIONS
SETPOINT
OPTIONS
OCCP02S
OCCDEFCS
ICVC CONFIGURATION
ICVC CONFIGURATION
ICVC CONFIGURATION
CONFIGURABLE
X
ICVC CONFIGURATION
ICVC CONFIGURATION
ICVC CONFIGURATION
ICVC CONFIGURATION
ICVC CONFIGURATION
ICVC CONFIGURATION
VFD_CONF
VFD_STAT
POWER
VFD_STAT
VFD_STAT
VFD_CONF
OVERRIDE
SETUP1
OVERRIDE
POWER
VFD_HIST
LEADLAG
LEADLAG
LL_MAINT
LL_MAINT
LEADLAG
LL_MAINT
LEADLAG
CAPACITY
SETPOINT
LL_MAINT
LEADLAG
LL_MAINT
LEADLAG
LL_MAINT
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
PARAMETER
Leaving Cond Liquid
Leaving Cond Liquid
Leaving Cond Liquid
LID Language
Line Active Current
Line Active Current (At Last Fault)
Line Active Voltage
Line Active Voltage (At Last Fault)
Line Current Imbalance (At Last Fault)
Line Current Ph 1(R)
Line Current Ph 1(R)(At Last Fault)
Line Current Ph 2(S)
Line Current Ph 2(S)(At Last Fault)
Line Current Ph 3(T)
Line Current Ph 3(T)(At Last Fault)
Line Frequency
Line Frequency (At Last Fault)
Line Kilowatts
Line Phase Reversal
Line Power Factor
Line Power Factor (At Last Fault)
Line Reactive Current (At Last Fault)
Line Reactive Voltage (At last Fault)
Line Volt Imbalance Time
Line Voltage Imbalance (At Last Fault)
Line Voltage Ph 1(RS)
Line Voltage Ph 1(RS)(At Last Fault)
Line Voltage Ph 2(ST)
Line Voltage Ph 2(ST)(At Last Fault)
Line Voltage Ph 3(TR)
Line Voltage Ph 3(TR)(at Last Fault)
Load Balance Option
Load Balance Option
Load Current Ph 1(U)
Load Current Ph 1(U)(At Last Fault)
Load Current Ph 2(V)
Load Current Ph 2(V)(At Last Fault)
Load Current Ph 3(W)
Load Current Ph 3(W)(At Last Fault)
Loadshed
Loadshed Function
Loadshed Function
Loadshed Timer
LOCAL
Local Network Device
Local Time Schedule
Local Time Schedule(OCCPC01S)
LOG OUT OF DEVICE
Low DC Bus Voltage
Low Line Voltage
MENU SOFTKEY
TABLE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SCHEDULE
SERVICE
SERVICE
STATUS
STATUS
CONTROL TEST
CONTROL TEST
VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
EQUIPMENT SERVICE
EQUIPMENT SERVICE
SCREEN NAME
CONFIGURABLE
CAPACITY
DEFAULT SCREEN
HEAT_EX
THERMISTORS
HEAT_EX
THERMISTORS
DEFAULT SCREEN
ICVC CONFIGURATION
X
POWER
VFD_HIST
POWER
VFD_HIST
VFD_CONF
X
VFD_CONF
X
POWER
VFD_STAT
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_STAT
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
VFD_CONF
X
VFD_CONF
X
POWER
VFD_STAT
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
SETUP1
X
LEADLAG
X
LL_MAINT
POWER
VFD_HIST
POWER
VFD_HIST
POWER
VFD_HIST
LOADSHED
LOADSHED
NET_OPT
LOADSHED
DEFAULT SCREEN
X
X
OCCP01S
X
OCCDEFCS
X
VFD_STAT
VFD_STAT
122
PARAMETER
Maximum Loadshed Time
Min. Load Point (T1,P1)(Hot Gas ByPass)
Minimum Output (Head Pressure Reference)
Model #
Motor Amps Not Sensed
Motor Current Imbalance (At Last Fault)
Motor Current% Imbalance
Motor Kilowatt Hours
Motor Kilowatts
Motor Nameplate KW
Motor Nameplate RPM
Motor Overload
Motor Overload
Motor Overload (At Last Fault)
Motor Power Factor
Motor Power Factor (At Last Fault)
Motor Rated Load Amps
Motor Rated Load KW
OCCP01S (Local Time Schedule)
OCCP02S (Ice Build Time Schedule)
OCCP03S (CCN Time Schedule)
OCCPC01S(Local Time Schedule)
OCCPC02S(Ice Build Time Schedule)
OCCPC03S(CCN Time Schedule)
Occupied?
Oil Heater Relay
Oil Heater Relay Test
Oil Pressure Acceptable?
Oil Pump Relay
Oil Pump Relay
Oil Pump Relay
Oil Reclaim Output
Oil Reclaim Output
Oil Reclaim Output Test
Oil Sump Temp
Oil Sump Temp
Oil Sump Temp
Oil Sump Temp
Password (SERVICE)
Password (VFD CONFIG DATA)
Percent Line Voltage
Percent Load Current
Percent Motor Kilowatts
PPM at 20 mA (Refrigerant Leak Option)
Pressure Transducers Control Test
PRESTART FAULT Time
PRIMARY MESSAGE
MENU SOFTKEY
TABLE
SERVICE
SERVICE
EQUIPMENT SERVICE
SERVICE
EQUIPMENT SERVICE
SERVICE
STATUS
SERVICE
VFD CONFIG DATA
STATUS
STATUS
SERVICE
SERVICE
VFD CONFIG DATA
STATUS
STATUS
SERVICE
VFD CONFIG DATA
SERVICE
VFD CONFIG DATA
SERVICE
VFD CONFIG DATA
SERVICE
VFD CONFIG DATA
STATUS
STATUS
SERVICE
STATUS
SERVICE
SERVICE
VFD CONFIG DATA
SERVICE
VFD CONFIG DATA
SCHEDULE
SCHEDULE
SCHEDULE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
CONTROL TEST
SERVICE
EQUIPMENT SERVICE
SERVICE
CONTROL TEST
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
STATUS
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
STATUS
STATUS
STATUS
STATUS
STATUS
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
CONTROL TEST
CONTROL TEST
CONTROL TEST
CONTROL TEST
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
123
SCREEN NAME
NET_OPT
OPTIONS
OPTIONS
ICVC CONFIGURATION
VFD_STAT
VFD_CONF
POWER
VFD_STAT
VFD_HIST
VFD_CONF
POWER
POWER
VFD_CONF
VFD_CONF
VFD_CONF
VFD_CONF
POWER
VFD_STAT
VFD_HIST
POWER
VFD_HIST
VFD_CONF
VFD_CONF
OCCP01S
OCCP02S
OCCP03S
OCCDEFCS
OCCDEFCS
OCCDEFCS
MAINSTAT
COMPRESS
DISCRETE OUTPUTS
SETUP1
PUMPS
COMPRESS
DEFAULT SCREEN
PUMPS
STARTUP
COMPRESS
PUMPS
STARTUP
HEAT_EX
STARTUP
OIL RECLAIM OUTPUT
COMPRESS
DEFAULT SCREEN
STARTUP
THERMISTORS
ICVC CONFIGURATION
VFD CONFIG DATA
DEFAULT SCREEN
MAINSTAT
POWER
MAINSTAT
POWER
POWER
POWER
POWER
OPTIONS
CONTROL TEST
LL_MAINT
LEADLAG
DEFAULT SCREEN
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
PARAMETER
Proportional Dec Band (Capacity Control)
Proportional ECL Gain (Capacity Control)
Proportional Inc Band (Capacity Control)
Pulldown Ramp Type:
PULLDOWN Time
PULLDOWN Timer
Pulldown: Delta T / Min
Pumpdown/Lockout Control Test
Pumpdown/Lockout Control Test
Pumps Control Test
Rated Line Amps
Rated Line Kilowatts
Rated Line Voltage
Re-alarm Time (Alarm Configuration)
Reclaim Delta T
Recovery Start Request (Lag Chiller)
Recovery Start Request (Standby Chiller)
Rectifier Overcurrent
Rectifier Overload
Rectifier Overtemp
Rectifier Power Fault
Rectifier Temperature (At Last Fault)
Recycle Control
Redline (Loadshed Function)
Reference #
Refrig Leak Alarm PPM (Refrigerant Leak Option)
Refrig Leak Sensor PPM
Relative Humidity
Relative Humidity
Remote Reset Option
Remote Reset Sensor
Remote Reset Sensor
Remote Start Contact
Remote Temp->Full Reset
Remote Temp->No Reset
RESET
Reset Alarm ?
RESET TYPE 1(Temperature Reset)
Restart Delta T (Recycle Control)
Run Status
Run Status (Lag Chiller)
Run Status (Standby Chiller)
RUNTM01E
Satisfied? (Pulldown)
Schedule Number (CCN Occupancy Config)
SECONDARY MESSAGE
Serial #
Service Ontime
SERVICE Password
Setpoint - ECL (Base Demand Limit Control Point)
Setpoint - LCL (Base Demand Limit Control Point)
Shunt Trip Relay
Shunt Trip Relay Test
Shutdown Delta T (Recycle Control)
MENU SOFTKEY
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
STATUS
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
STATUS
TABLE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
EQUIPMENT SERVICE
CONTROL TEST
SCREEN NAME
SETUP2
SETUP2
SETUP2
RAMP_DEM
LL_MAINT
LEADLAG
LL_MAINT
CONTROL TEST
Pumpdown/Lockout
CONTROL TEST
VFD_CONF
VFD_CONF
VFD_CONF
NET_OPT
HEAT_EX
LL_MAINT
LL_MAINT
VFD_STAT
POWER
VFD_STAT
VFD_STAT
OVERRIDE
SETUP1
OVERRIDE
POWER
VFD_HIST
SETUP1
LOADSHED
ICVC CONFIGURATION
OPTIONS
MAINSTAT
SETUP1
OPTIONS
POWER
OPTIONS
ICVC_PWD
MAINSTAT
THERMISTORS
MAINSTAT
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
X
SERVICE
EQUIPMENT SERVICE
TEMP_CTL
X
DEFAULT SCREEN
ICVC_PWD
TEMP_CTL
TEMP_CTL
TEMP_CTL
SETUP1
MAINSTAT
LL_MAINT
LL_MAINT
RUNTM01E
LL_MAINT
NET_OPT
DEFAULT SCREEN
ICVC CONFIGURATION
MAINSTAT
ICVC CONFIGURATION
SETPOINT
SETPOINT
STARTUP
DISCRETE OUTPUTS
SETUP1
X
X
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SETPOINT
SETPOINT
STATUS
SERVICE
SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
EQUIPMENT SERVICE
124
X
X
X
X
X
X
X
X
X
PARAMETER
Skip Frequency 1
Skip Frequency 2
Skip Frequency 3
Skip Frequency Band
Software Part #
Spare Alert/Alarm Enable
Spare Safety Input
Spare Temp #1 Enable (Spare Alert/Alarm Enable)
Spare Temp #1 Limit (Spare Alert/Alarm Enable)
Spare Temp #2 Enable (Spare Alert/Alarm Enable)
Spare Temp #2 Limit (Spare Alert/Alarm Enable)
Spare Temperature 1
Spare Temperature 1
Spare Temperature 1
Spare Temperature 2
Spare Temperature 2
Spare Temperature 2
Stall Delta % Amps (Stall Protection)
Stall Protection
Stall Protection Counts
Stall Time Period (Stall Protection)
STANDBY % Capacity
STANDBY Address
STANDBY CHILLER: Mode
Start Acceleration Fault
Start Advance (Daylight Savings)
Start Complete
Start Complete
Start Day of Week (Daylight Savings)
Start Inhibit Timer
Start Month (Daylight Savings)
Start Time (Daylight Savings)
Start Week (Daylight Savings)
Start/Stop (Lag Chiller)
Start/Stop (Standby Chiller)
Starts in 12 Hours
Stop Back (Daylight Savings)
Stop Complete
Stop Complete
Stop Day of Week (Daylight Savings)
Stop Fault
Stop Month (Daylight Savings)
Stop Time (Daylight Savings)
Stop Week (Daylight Savings)
System Alert/Alarm
Target VFD Speed
Target VFD Speed
Temp Pulldown Ramp/Min (Control Point)
Temperature Reset
Temperature Reset
Terminate Lockout
Thermistors Control Test
TIME AND DATE
Time Broadcast Enable
Torque Current
Torque Current (At Last Fault)
Total Compressor Starts
Total Error + Resets (Capacity Control)
MENU SOFTKEY
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
SERVICE
STATUS
SERVICE
TABLE
VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
VFD CONFIG DATA
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
125
SCREEN NAME
VFD_CONF
VFD_STAT
VFD_CONF
VFD_CONF
VFD_CONF
VFD_CONF
OPTIONS
ICVC CONFIGURATION
SETUP1
STARTUP
SETUP1
SETUP1
SETUP1
SETUP1
COMPRESS
LL_MAINT
THERMISTORS
COMPRESS
LL_MAINT
THERMISTORS
OPTIONS
OPTIONS
COMPRESS
OPTIONS
LEADLAG
LEADLAG
LEADLAG
LL_MAINT
VFD_STAT
BRODEF
STARTUP
VFD_STAT
BRODEF
MAINSTAT
BRODEF
BRODEF
BRODEF
LL_MAINT
LL_MAINT
MAINSTAT
BRODEF
STARTUP
VFD_STAT
BRODEF
VFD_STAT
BRODEF
BRODEF
BRODEF
MAINSTAT
CAPACITY
COMPRESS
TEMP_CTL
MAINSTAT
TEMP_CTL
TERMINATE LOCKOUT
CONTROL TEST
TIME AND DATE
BRODEF
POWER
VFD_HIST
MAINSTAT
CAPACITY
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
PARAMETER
Tower Fan Relay High
Tower Fan Relay High Test
Tower Fan Relay Low
Tower Fan Relay Low Test
Transducer Voltage Ref
US IMP/Metric
Values At Last Fault:
Vaporizer Heater
Vaporizer Heater
Vaporizer Heater Test
Vaporizer Temp
Vaporizer Temp
Vaporizer Temp
VFD Checksum Error
VFD Cold Plate Temp
VFD Cold Plate Temp (At Last Fault)
VFD Comm Fault
VFD CONFIG DATA Password
VFD Coolant Flow
VFD Coolant Flow
VFD Coolant Solenoid Test
VFD Delta
VFD Delta (Capacity Control)
VFD Enclosure Temp
VFD Enclosure Temp (At Last Fault)
VFD Fault
VFD Fault Code
VFD Fault Code (At Last Fault)
VFD FAULT HISTORY
VFD Gain
VFD Gain (VFD Control)
VFD Gateway Version #
VFD Inverter Version #
VFD Maximum Speed (VFD Control)
VFD Minimum Speed (VFD Control)
VFD Power On Reset
VFD Rectifier Version #
VFD Speed Control
VFD Speed Output
VFD Speed Output
VFD Speed Output
VFD Start
VFD Start Inhibit
WSM Active?
MENU SOFTKEY
SETPOINT
STATUS
SERVICE
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
STATUS
STATUS
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
STATUS
SERVICE
STATUS
SERVICE
STATUS
STATUS
SERVICE
SERVICE
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
STATUS
SERVICE
SERVICE
STATUS
STATUS
STATUS
STATUS
SERVICE
TABLE
CONTROL TEST
CONTROL TEST
CONTROL TEST
EQUIPMENT SERVICE
CONTROL TEST
CONTROL TEST
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
EQUIPMENT SERVICE
126
SCREEN NAME
SETPOINT
STARTUP
DISCRETE OUTPUTS
STARTUP
DISCRETE OUTPUTS
ICVC CONFIGURATION
VFD_HIST
COMPRESS
COMPRESS
SETUP2
DISCRETE OUTPUTS
STARTUP
COMPRESS
HEAT_EX
VFD_STAT
POWER
VFD_HIST
VFD_STAT
VFD CONFIG DATA
HEAT_EX
POWER
DISCRETE OUTPUTS
COMPRESS
CAPACITY
POWER
VFD_HIST
VFD_STAT
VFD_STAT
VFD_HIST
VFD_HIST
CAPACITY
SETUP2
VFD_STAT
VFD_STAT
SETUP2
SETUP2
VFD_STAT
VFD_STAT
SETUP2
CAPACITY
COMPRESS
STARTUP
STARTUP
VFD_STAT
WSMCHLRE
CONFIGURABLE
X
X
X
X
X
X
X
X
X
X
X
X
X
INDEX
Abbreviations and explanations 4
After limited shutdown 67
Attach to network device control 44
Automatic soft stop amps threshold 47
Auto. restart after power failure 40
Before initial start-up 48-64
Carrier Comfort Network® Interface 58
Capacity control 12
Capacity override 36
Chilled liquid recycle mode 47
Chiller control module (CCM) 98
Chiller dehydration 55
Chiller familiarization 4-8
Chiller identification nameplate 4
Chiller start-up (prepare for) 66
Chillers with storage tanks 70
Chiller tightness (check) 49
Cold weather operation 67
Compressor bearing maintenance 77
Compressor minimum speed override 36
Compressor rotor check 77
Condenser 8
Condenser freeze prevention 39
Condenser pump control 39
Control algorithms checkout procedure 80
Control center 8
Control center (inspect) 73, 77
Control modules 98
Controls 12-46
Controls (definitions) 12
Control test 61, 81
Cooler 8
ICVC operation and menus 15
ICVC parameter index 118-126
Default screen freeze 36
Defective processor modules (replacing) 101
Demand limit control option 40
Design set points (input) 59
Display messages (checking) 79
Equipment required 48
Extended shutdown (preparation for) 66
Extended shutdown (after) 67
Gateway status LEDs 102
General controls overview 12
General maintenance 72, 73
Ground fault troubleshooting 58
Head pressure output reference 41
Heat exchanger tubes (inspect) 77
High altitude locations 62
Hot gas bypass (optional) algorithm 40
Identify the VFD 55
Initial start-up 64, 65
Initial start-up (preparation) 64
Initial start-up checklist for 23XRV
hermetic screw liquid chiller CL-1 to CL-12
Input power wiring 57
Inspect liquid piping 55
Inspect wiring 57
Instruct the customer operator 65
Introduction 4
Job data required 48
Lead/lag control 42
Leak test chiller 49
Liquid/brine temperature reset 40
Local occupied schedule (input) 59
Local start-up 46
Lubrication cycle 10-12
Lubrication cycle (details) 10
Lubrication cycle (summary) 10
Lubrication system (check) 73
Module operation (notes) 98
Motor-compressor 8
Motor cooling cycle 10
Motor insulation 77
Muffler 8
Oil and oil filter changes 73
Oil charge 48
Oil circuit valves (open) 48
Oil heater 74
Oil pressure and compressor
stop (check) 65
Oil reclaim system 12
Oil specification 74
Oil strainers 74
Oil sump temperature control 36, 38
Operating instructions 66-68
Operating the optional pumpout unit 69
Operator duties 66
Optional pumpout compressor
Liquid piping (check) 55
Optional storage tank and
pumpout system (using) 48
Optional pumpout system controls
and compressor (check) 62
Optional pumpout system maintenance 78
Ordering replacement chiller parts 78
Overview (troubleshooting guide) 78
Physical data 103
PIC III system components 12
PIC III system functions 34
Preparation (pumpout and
refrigerant transfer procedures) 69
Pressure transducers 61, 79
Prevent accidental start-up 65
Pumpout and refrigerant
transfer procedures 69-72
Ramp loading 36
Refrigerant (adding) 72
Refrigerant (adjusting the charge) 72
Refrigerant charge (trim) 73
Refrigerant filter/drier 74
Refrigerant float system (inspect) 75
Refrigerant into chiller (charge) 63
Refrigerant leak rate 72
Refrigerant leak testing 72
Refrigerant leak detector 39
Refrigerant properties 72
Refrigerant (removing) 72
Refrigerant tracer 49
Refrigeration cycle 8-10
Refrigeration log 67
Relief valves (check) 55
Relief valves and piping (inspect) 77
Remote start/stop contacts 38
Remote reset of alarms 39
Repair the leak retest
and apply standing vacuum test 73
Running system (check) 66
Safety and operating
controls (check monthly) 73
Safety considerations 1
Safety controls 35
Safety shutdown 48
Scheduled maintenance 73-78
Service configurations (input) 59
Service ontime 73
Service operation 45
Shipping packaging (remove) 48
Shunt trip 36
Shutdown sequence 47
Software configuration 59
Spare alarm contacts 39
Spare safety inputs 38
Start the chiller 66
Starter (check) 57
Start-up/shutdown/recycle sequence 46-48
Stop the chiller 66
Storage vessel (optional) 8
System components 4
Temperature sensors (checking) 79
Test after service repair or
major leak 72
Tighten all gasketed joints 48
Tower fan relay low and high 39
Troubleshooting guide 78-117
Vaporizer temperature control 36
127
VFD refrigerant strainers 74
Water/brine leaks 77
Water/brine treatment 77
Weekly maintenance 73
Copyright 2006 Carrier Corporation
Catalog No. 532-310
Printed in U.S.A.
Form 23XRV-1SS
Pg 128
9-06
Replaces: New
Book 2
Tab 5e
INITIAL START-UP CHECKLIST
FOR 23XRV HERMETIC SCREW LIQUID CHILLER
(Remove and use for job file.)
MACHINE INFORMATION:
NAME
ADDRESS
CITY
JOB NO.
MODEL
ZIP
STATE
S/N
DESIGN CONDITIONS
TONS
(kW)
BRINE
FLOW
RATE
TEMPERATURE
IN
TEMPERATURE PRESSURE
OUT
DROP
PASS
SUCTION
TEMPERATURE
COOLER
CONDENSER
******
From Chiller Nameplate: Line Voltage
Rated Line Amps
From VFD Nameplate: I.D. No.:
Input Rating
VFD Serial Number ___________________________________________
Mfd in _____________________________________ on _____________
REFRIGERANT:
CONDENSER
TEMPERATURE
******
Type:
CARRIER OBLIGATIONS:
Overload Trip Amps
Charge
Assemble. . . . . . . . . . . . . . . . . . .
Leak Test . . . . . . . . . . . . . . . . . . .
Dehydrate . . . . . . . . . . . . . . . . . .
Charging . . . . . . . . . . . . . . . . . . .
Operating Instructions
Yes
Yes
Yes
Yes
No
No
No
No
Hrs.
START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS
JOB DATA REQUIRED:
1. Machine Installation Instructions . . . . . . . . . . . . . . . . . . Yes
No
2. Machine Assembly, Wiring and Piping Diagrams . . . . . . Yes
No
3. Starting Equipment Details and Wiring Diagrams. . . . . . Yes
No
4. Applicable Design Data (see above) . . . . . . . . . . . . . . . . Yes
No
5. Diagrams and Instructions for Special Controls . . . . . . . Yes
No
INITIAL MACHINE PRESSURE:
YES
NO
Was Machine Tight?
If Not, Were Leaks Corrected?
Was Machine Dehydrated After Repairs?
CHECK OIL LEVEL AND RECORD:
3/4
1/2 Oil sump sight glass
1/4
ADD OIL:
Amount:
Yes
No
3/4
1/2 Strainer housing sight glass
1/4
RECORD PRESSURE DROPS:
CHARGE REFRIGERANT:
Cooler
Initial Charge
Condenser
Final Charge After Trim
Book 2
Catalog No. 532-310
Printed in U.S.A.
Form 23XRV-1SS
Pg CL-1
9-06
Replaces: New
Tab 5e
Yes
Yes
No
No
Line Voltage:
FIELD-DISASSEMBLED CHILLERS ONLY:
Megger Test Motor if the VFD is removed from the chiller.
Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T1, T2, T3.) Do not megger VFD;
disconnect leads to motor and megger the leads.
MEGGER MOTOR
“PHASE TO PHASE”
T1-T2
T1-T3
T2-T3
“PHASE TO GROUND”
T1-G
T2-G
T3-G
10-Second Readings:
60-Second Readings:
Polarization Ratio:
CONTROLS: SAFETY, OPERATING, ETC.
Verify parameters in VFD_conf screen.
Yes
No
Perform Controls Test
Yes
No
PIC III CAUTION
COMPRESSOR MOTOR AND CONTROL CENTER MUST BE PROPERLY AND INDIVIDUALLY
CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH
CERTIFIED DRAWINGS).
Water/Brine Pump Control
Can the Carrier controls independently start the pumps?
Chilled Liquid Pump
Yes
Yes
No
No
INITIAL START:
Check Position of all Valves:
Isolation Valves (See Fig. 2, 43-45)
VALVE
Discharge
Cooler Inlet
Hot Gas Bypass
Vaporizer Condenser Gas
Oil Pump
Oil Filter
Oil Pressure Regulator
Filter/Drier
Filter/Drier
VFD Refrigerant Cooling Inlet
VFD Refrigerant Cooling Drain
LOCATION
Under Muffler
Next to economizer or under cooler
Between cooler and condenser
Next to oil pump inlet
Downstream of oil filter
Under oil sump next to oil pressure regulator
Next to condenser float chamber
Under condenser near filter/drier
Under compressor discharge
OPEN
________
________
________
________
________
________
________
________
________
________
________
Fully Front Seated or Fully Back Seated
Fully Front Seated or Fully Back Seated
________
________
CLOSED
On cooler relief valve tree
Under cooler
On condenser relief valve tree
On condenser float valve chamber
Under oil sump
________
________
________
________
________
Relief Valve Three-Way Valves
Cooler (if installed)
Condenser
Service Valves
Cooler Refrigerant Charging Valve
Cooler Refrigerant Pumpout Valve
Condenser Refrigerant Charging Valve
Condenser Refrigerant Pumpout Valve
Oil Sump Charging/Drain Valve
CL-2
Yes
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
INSPECT WIRING AND RECORD ELECTRICAL DATA:
Verify 6″ clearance surrounding all Control Center louvers
Visually inspect down through top of power module for debris
Start Liquid Pumps and Establish Liquid Flow
Oil Level OK and Oil Temperature OK
Oil Pressure
Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise?
Yes*
*If yes, determine cause.
START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:
A: Trim charge and record under Charge Refrigerant Into Chiller section on page 63.
B: Complete any remaining control calibration and record under Controls section (pages 12-46).
C: Take at least two sets of operational log readings and record.
D: After machine has been successfully run and set up, shut down and mark shutdown oil levels.
E: Give operating instructions to owner’s operating personnel.
Hours Given:
Hours
F: Call your Carrier factory representative to report chiller start-up.
G: Register LiquiFlo2 VFD start up on www.automation.rockwell.com/complete1/warp.
H: Return a copy of this completed checklist to the local Carrier Service office.
SIGNATURES:
CARRIER
TECHNICIAN
CUSTOMER
REPRESENTATIVE
DATE
DATE
CL-3
No
DESCRIPTION
Base Demand Limit
LCL Setpoint
ECL Setpoint
Ice Build Setpoint
RANGE
40 to 100
10 to 60 (-12.2-15.6)
15 to 65 (-9.4-18.3)
15-60 (-9.4-15.6)
55 to 105 (-13-41)
Upload all Control Configuration tables via Service Tool
Yes
UNITS
%
° F (° C)
° F (° C)
° F (° C)
° F (° C)
DEFAULT
100
50.0 (10.0)
60.0 (15.6)
40 (4.4)
75 (23.9)
No
ICVC Software Part # (See ICVC CONFIGURATION Screen):
ICVC Controller Identification (See ICVC CONFIGURATION Screen): BUS:
VFD Gateway Version # (See VFD_STAT Screen):
VFD Inverter Version # (See VFD_STAT Screen):
VFD Rectifier Version # (See VFD_STAT Screen):
CL-4
ADDRESS:
VALUE
23XRV PIC III SETPOINT TABLE CONFIGURATION SHEET
23XRV PIC III LOCAL TIME SCHEDULE CONFIGURATION SHEET OCCPC01S
Day Flag
M T W T F S
S
H
Occupied
Time
Unoccupied
Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
ICE BUILD 23XRV PIC III TIME SCHEDULE CONFIGURATION SHEET OCCPC02S
Day Flag
M T W T F S
S
H
Occupied
Time
Unoccupied
Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is UNOCCUPIED 24 hours/day.
23XRV PIC III CCN TIME SCHEDULE CONFIGURATION SHEET OCCPC03S
Day Flag
M T W T F S
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
CL-5
S
H
Occupied
Time
Unoccupied
Time
DESCRIPTION
RANGE
480-480
UNITS
VOLTS
DEFAULT
480
60.0-101
Hz
70
Rated Line Voltage
346-480
VOLTS
460
Rated Line Amps
10-5000
AMPS
200
Rated Line Kilowatts
0-999999
KW
100
Motor Rated Load KW
0-999999
KW
100
Motor Rated Load Amps
10-5000
AMPS
200
10-5000
AMPS
100
Motor Nameplate RPM
1500-3030
Motor Nameplate KW
(0=4 k Hz, 1=2 k Hz)
Skip Frequency 1
0-999999
0.0-102
Hz
102
Skip Frequency 2
0.0-102
Hz
102
Skip Frequency 3
0.0-102
Hz
102
Skip Frequency Band
0.0-102
Hz
0
1-10
%
10
Line Volt Imbalance Time
1-10
SEC
10
5-40
%
40
1-10
SEC
10
Motor Current % Imbalance
5-40
%
40
1-10
SEC
10
Increase Ramp Time
5-60
SEC
30
Decrease Ramp Time
5-60
SEC
30
0/1
DSABLE/ENABLE
DSABLE
2672
KW
0/1
100
0
CL-6
VALUE
23XRV PIC III VFD_CONF TABLE CONFIGURATION SHEET
23XRV PIC III OPTIONS TABLE CONFIGURATION SHEET
DESCRIPTION
Auto Restart Option
RANGE
0/1
0/1
40 to 100
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
DEFAULT
DSABLE
DSABLE
100
Hot Gas Bypass
HGBP Option
0,1,2
0=DSABLE
1=HGBP
2=LOW LOAD HGBP
0=DSABLE
0.5 to 20
(.3 to 11.1)
30 to 170
(206.9 to 1172.2)
ˆF
(ˆC)
PSI
(kPa)
1.5
(.8)
150
(1034.2)
0.5 to 20
(.3 to 11.1)
30 to 250
(206.9 to 1724)
0.5 to 3
(.3 to 1.7)
0.5-10 (0.3-5.6)
1.0-10 (0.6-5.6)
ˆF
(ˆC)
PSI
(kPa)
ˆF
(ˆC)
^F (^C)
^F (^C)
4
(2.2)
200
(1379)
1
(.6)
2.0 (1.1)
4.0 (2.2)
5 to 20
7 to 10
%
MIN
10
8
0/1
0-2
DSABLE/ENABLE
DSABLE
0
0/1
0/1
0-99999
0-99999
DSABLE/ENABLE
DSABLE/ENABLE
DSABLE
DSABLE
1000
20
20-85
(138-586)
20-85
(138-586)
0 to 100
PSI
(kPa)
PSI
(kPa)
%
25
(172)
35
(241)
0
Min. Load Point (T1, P1)
HGBP Delta T1
HGBP Delta P1
Full Load Point (T2, P2)
HGBP Delta T2
HGBP Delta P2
HGBP Deadband
HGBP On Delta T
HGBP Off Delta T
Stall Protection
Stall Delta % Amps
Stall Time Period
Ice Build Control
Ice Build Option
(0=TEMP, 1=Contact, 2=Both)
Ice Build Recycle
PPM at 20 mA
Refrigerant Leak Alarm PPM
Minimum Output
CL-7
VALUE
DESCRIPTION
Cond Press Override
Chilled Medium
Chilled Liquid Deadband.
Evap Approach Alert
Cond Approach Alert
RANGE
150 - 200
(66 - 93)
145 - 166
(1000 - 1145)
125 to 160
(52 to 71)
155 to 170
(68 to 77)
155 to 170
(68 to 77)
UNITS
°F
(° C)
PSI
(kPa)
°F
(° C)
°F
(° C)
°F
(° C)
DEFAULT
200
(93)
145
(1000)
140
(60)
160
(71)
160
(71)
0/1
0.5 to 2.0
(0.3 to 1.1)
10 to 40.0
(–12.2 to 4.4)
2.0 to 5.0
(1.1 to 2.8)
0.5 to 15
(0.3 to 8.3)
0.5 to 15
(0.3 to 8.3)
–20 to 35
(–28.9 to 1.7)
WATER/BRINE
ˆF
(ˆC)
°F
(° C)
ˆF
(ˆ C)
ˆF
(ˆC)
ˆF
(ˆC)
°F
(° C)
WATER
1.0
(0.6)
33
(0.6)
3
(1.7)
5
(2.8)
6
(3.3)
34
(1.1)
0/1
0.5 to 50.0
(3.4 to 344.8)
0.5 to 50.0
(3.4 to 344.8)
15 to 300
0.5 to 5
DS/ENABLE
PSI
(kPa)
PSI
(kPa)
SEC
MIN
DSABLE
5.0
(34.5)
5.0
(34.5)
45
5
2.0 to 10.0
(1.1 to 5.6)
0.5 to 4.0
(0.3 to 2.2)
ˆF
(ˆ C)
ˆF
(ˆ C)
5
(2.8)
1
(0.6)
Recycle Control
Restart Delta T
Shutdown Delta T
SPARE ALERT/ALARM ENABLE
Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Limit
Spare Temp #2 Limit
0 to 4
–40 to 245
(–40 to 118)
0 to 4
–40 to 245
(–40 to 118)
°F
(° C)
°F
(° C)
CL-8
0
245
(118)
0
245
(118)
VALUE
23XRV PIC III SETUP1 TABLE CONFIGURATION SHEET
23XRV PIC III SETUP2 TABLE CONFIGURATION SHEET
DESCRIPTION
Capacity Control
Proportional Inc Band
Proportional Dec Band
Proportional ECL Gain
VFD Control
VFD Gain
VFD Minimum Speed
VFD Maximum Speed
0 = Normal, 1 = Service
STATUS
UNITS
2 to 10
2 to 10
1 to 3
0.1 to 1.5
15 to 50
15 to 100
0 to 1
DEFAULT
6.5
6.0
2.0
%
%
CL-9
0.75
20
100
0
VALUE
DESDRIPTION
Lead Lag Control
LEAD/LAG Configuration
DSABLE=0, LEAD=1,
LAG=2, STANDBY=3
Load Balance Option
LAG % Capacity
LAG Address
LAG START Timer
LAG STOP Timer
PULLDOWN Timer
STANDBY % Capacity
STANDBY Address
RANGE
UNITS
0 to 3
0/1
0/1
25 to 75
1 to 236
2 to 60
2 to 60
2 to 30
1 to 30
0/1
25 to 75
1 to 236
DEFAULT
0
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
MIN
DSABLE/ENABLE
%
CL-10
DSABLE
DSABLE
50
92
10
10
5
2
DSABLE
50
93
VALUE
23XRV PIC III LEADLAG TABLE CONFIGURATION SHEET
23XRV PIC III RAMP_DEM TABLE CONFIGURATION SHEET
DESCRIPTION
Pulldown Ramp Type:
Select: Temp=0, kW=1
Demand Limit and kW Ramp
Demand Limit Source
Select: Amps=0, kW=1
Amps or kW Ramp % Min
Demand Limit At 20 mA
20 mA Demand Limit Opt
RANGE
UNITS
DEFAULT
0/1
1
0/1
0
5 to 20
3 to 15
40 to 100
0/1
5 to 60
%
%
DSABLE/ENABLE
MIN
VALUE
10
10
40
DSABLE
15
23XRV PIC III TEMP_CTL TABLE CONFIGURATION SHEET
DESCRIPTION
ECL Control Option
Temp Pulldown Ramp/Min
RANGE
UNITS
DEFAULT
0/1
2 to 10
(1.1 to 5.6)
DSABLE/ENABLE
ˆF
(ˆC)
DSABLE
3
(1.7)
–30 to 30
(–17 to 17)
ˆF
(ˆC)
10
(6)
–40 to 245
(–40 to 118)
–40 to 245
(–40 to 118)
–30 to 30
(–17 to 17)
°F
(° C)
°F
(° C)
ˆF
(ˆC)
85
(29)
65
(18)
10
(6)
0 to 15
(0 to 8)
0 to 15
(0 to 8)
–30 to 30
(–17 to 17)
ˆF
(ˆC)
ˆF
(ˆC)
ˆF
(ˆC)
10
(6)
0
(0)
5
(3)
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA
RESET TYPE 2
Remote Temp (– > No Reset)
Remote Temp (– > Full Reset)
Degrees Reset
RESET TYPE 3
CHL Delta T (– > No Reset)
CHL Delta T (– > Full Reset)
Degrees Reset
Enable Reset Type
0 to 3
0
CL-11
VALUE
DESCRIPTION
Time Broadcast Enable
Daylight Savings
Start Month
Start Day of Week
Start Week
Start Time
Start Advance
Stop Month
Stop Day of Week
Stop Week
Stop Time
Stop Back
RANGE
0/1
1 to 12
1 to 7
1 to 5
00:00 to 24:00
0 to 360
1 to 12
1 to 7
1 to 5
00:00 to 24:00
0 to 360
UNITS
DSABLE/ENABLE
HH:MM
MIN
MIN
DEFAULT
DSABLE
VALUE
4
7
1
02:00
0
10
7
5
02:00
0
Copyright 2006 Carrier Corporation
Catalog No. 532-310
Printed in U.S.A.
Form 23XRV-1SS
Pg CL-12
10-06A 9-06
Replaces: New
Book 2
Tab 5e
23XRV BROADCAST (BRODEF) CONFIGURATION SHEET

Start-Up, Operation and Maintenance Instructions

Transcription

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